Reducing downtime for truck operators

What was the Problem?

• Every truck in the UK has to have a safety and condition inspection every 6-weeks
• The management and team of a major truck dealer were introduced to Lean thinking
• They then saw the waste in every regular inspection: walking, searching, variation of method
• Interruption of other techs to help with the inspection – affecting quality and efficiency

Countermeasures:

• Observe and map process to identify waste
• Propose experiment of two technicians working together to do a truck inspection
• Test and improve new method and layout of tools
• Establish standard method (best way we know how, today) and teach it to others

Two technicians doing Express Truck Inspection

Outcomes:

• 2 technicians, synchronised, doing minimum of 2.5 hours work in 1 hour
• Next target: 45 mins = 166% efficient
• Other technicians’ work is more efficient as they are not interrupted
• Parking problems on site are significantly reduced
• Appointment time means customers now bring trucks in midweek for inspections
• They plan for driver to wait for 1 hour, mid-route instead of leaving the truck over the weekend
• Work previously turned away at weekend now accepted

Profit increase estimated at £180,000 p.a.