Optimization of Sheath Manufacturing Workflow for Angio-Seal Production Design

Abstract

The manufacturing workflow of the Sheath component at Terumo Medical Corporation was identified as a critical area for improvement due to excessive lead time and redundant processing. Using the DMAIC methodology and Value Stream Mapping (VSM), the project focused on consolidating two separate work orders—Tipped Tube and Sheath—into a single streamlined process. Time studies and root cause analysis revealed inventory wait time as the main non-value-added contributor. The implementation eliminated multiple redundant steps, such as reconciliation, kitting, and double handling. Post-implementation results included a 43% lead time reduction, lower work-in-process inventory, improved resource utilization (Expeditor, QA, Warehouse), and enhanced operational efficiency. Financial analysis projected annual savings of approximately $118,000, reinforcing the sustainability and impact of the improvement. The success of this initiative was driven by cross-functional collaboration and supports Terumo’s commitment to continuous improvement and high-quality manufacturing standards. Key Terms ⎯ DMAIC, Inventory Reduction, Lean Manufacturing, Root Cause Analysis.