Ford Motor Company - Electronics Division

LEAD TIME
(from release of material until shipping)
AVERAGE ON ALL SITES FOR ALL PRODUCTS

• Before improvement project: 10.6 days
• After two years of implementing JIT: 8.5 days
• After one year of implementing TOC: 2.2 days
• Currently: Less than two shifts

More reported results:

• Customer satisfaction improved by more than 75%
• Able to move to real time SPC on the floor
• Responsiveness and learning 300% faster
• 20% more floor space allowing introduction of new products
• Material handling and tracking reduced 50%
• Facilities investment reduced 25%
• Suggestions process went from 150 days to 10 days
• Scheduling process went from 16 days to 5 days to 1 day