**Client Overview**
GAL Manufacturing, a division of Hollister Whitney Company, specializes in producing elevator assemblies for major elevator manufacturers. As a tier-one vendor, GAL operates in a highly competitive industry where meeting delivery deadlines and maintaining "least-cost" vendor status are critical. The company constantly seeks ways to reduce waste and improve operational efficiency.
**Challenge**
One of GAL’s key challenges was the lack of real-time monitoring on its fully manual assembly lines. The traditional method required operators to log production and non-production time at the end of their shifts, leading to inaccuracies and delays in actionable insights. To remain competitive, GAL needed a streamlined, real-time data capture solution that operators could easily adopt, even in a dynamic production environment with frequently changing assembly standards and staffing.
**Solution**
GAL partnered with TSRB Systems LLC to develop a flexible and cost-effective solution tailored to their unique needs. TSRB implemented its **Manufacturer Print Q Server**, introducing innovative features to transform GAL’s manual processes into a seamless, automated workflow:
1. **Barcode Integration**:
TSRB connected scanners and printers to each assembly line, enabling the dynamic printing of identifying barcodes. Operators could generate and affix these barcodes to assemblies, ensuring traceability throughout the production process.
2. **ERP System Integration**:
Print Q integrated with GAL’s ERP system, mining order data to generate a comprehensive picklist for assemblies to be built and shipped. This integration automated order tracking and reduced the need for manual entry.
3. **Real-Time Data Capture**:
As assemblies moved through operations, they were scanned at the beginning and end of each stage. This provided real-time takt time information, allowing GAL to accurately measure throughput and identify bottlenecks.
4. **Adaptability to Dynamic Standards**:
One of the solution’s standout features was its ability to adapt to GAL’s frequently changing assembly standards and fluctuating staffing levels. Print Q’s flexibility ensured smooth operations regardless of daily shifts in production requirements.
**Results**
The deployment of TSRB’s Print Q solution delivered measurable improvements across GAL’s operations:
- **Enhanced Efficiency**: Operators quickly adopted the barcode-driven process, significantly reducing time spent on manual data logging.
- **Accurate Costing and Analysis**: Real-time takt time data enabled GAL to better understand production costs and optimize assembly line throughput.
- **Reduced Waste**: The system’s ability to identify underperforming lines allowed GAL to address inefficiencies proactively.
- **Custom Operator Experience**: Tailored workflows ensured that operators could seamlessly adjust to dynamic production standards, minimizing disruptions.
- **Improved Vendor Standing**: With streamlined operations and reduced costs, GAL reinforced its position as a reliable and cost-effective tier-one vendor.
**Conclusion**
By leveraging TSRB Systems’ Manufacturer Print Q Server, GAL Manufacturing successfully transformed its manual assembly lines into a model of efficiency and adaptability. This partnership not only addressed GAL’s immediate challenges but also provided a scalable foundation for future operational enhancements, ensuring the company remains a leader in its industry.