Two weeks after having raised the awareness of the management levels, the first workshop started as "flagship project". For this workshop a workstation was selected in the gripper assembly at which similar grippers in different scales are assembled.
During the task analysis, the workshop team detected rapidly enormous potential that should be fully utilized. The major concerns were the lacking of required tools at the workstation, lengthy routes, too many preparatory jobs which had nothing to do with the assembly and no flexibility at the individual assembly tables because the materials were suitable only for one size.
Reorganization suggestions were elaborated and were implemented to appr. 90% still during the workshop week.
The result was really impressive: The number of the assembly tables was reduced by 50%, the remaining workstations are now suitable for several sizes of grippers and all tools required are within easy reach and completely available at the assembly table.