Leadership and people’s participation and commitment were key throughout this lean transformation project.

SEINSA (Automotive)

Seinsa is dedicated to the manufacture of technical rubber elements for brake parts. It provides: Parts and repair kits for brake assemblies, clutches, transmissions, steerings and shock absorbers. Any other element of car repairs and general pieces of rubber, thermoplastic, as well as complementary metal elements. Founded in 1972 in a small village in Navarra, the company has become a European benchmark in the world of automotive aftermarket parts, diversifying its products and services. Today, it employs more than 200 people in the factories in Navarra and India.

In recent years, the company has grown sales by some 30% annually, a situation that has affected the service level and the process capacity. The scope of the project was the deployment of a pull system in their facilities in Navarra that would help the company to reduce delivery times.

The specific objectives of the improvement actions carried out were:

  • Reduce delivery time by 50%
  • Eliminate unnecessary movements of products
  • Optimize floor space
  • Standardize the preparation of MOs
  • Streamline packaging process

Behind the progress of this lean transformation project, we highlight three key elements: Leadership The creation of a multidisciplinary team (quality, engineer, logistics, production, administration) where different approaches and needs converge Members’ involvement from top to down

Starting point

  • Chaotic flows
  • Unfinished orders on backlog
  • Packaging positions on standby due to not having MOs prepared
  • Workers searching for material
  • Shortages of some raw materials and high stocks of others
  • No operational warehouse management system
  • Workers don’t have an active role in the improvements

What we do

  • Setting up the team project
  • VSM
  • Implementing a Kanban supermarket for:
    • Finished products
    • Components
  • Improving preparation and packaging stations
  • Change of warehouse layout
  • Implementing a daily operational management system in plants, operational processes and workstations

Results driven

-33%

Delivery time

+40%

Packaging process capacity

-22%

Stock reduction

-50%

Transportation and distance covered