Optimization of the Production Process of Transfer Switch in a Manufacturing Environment

Abstract

This project aimed to optimize the manufacturing process of ATS-100A automatic transfer switches in a manufacturing environment. Production was limited to 11 units per week on average due to inefficiencies, bottlenecks, and non-value-added activities. When the project began, in the first five weeks 55 units were produced compared to 120 planned units, evidenced by a difference of 65 units. The DMAIC methodology was applied to analyze the process, including time studies at workstations and the use of tools such as the Pareto chart to identify root causes. In the improvement phase, actions such as the establishment of standards, unification of production plans, and definition of minimums and maximums in inventories were implemented. These improvements aimed to reduce cycle times and increase the manufacturing production output and capacity to 24 units per week.