Delivering Excellence: Transforming Production with the Model Line Approach


In the fast-paced world of manufacturing, delivering top-quality products efficiently is essential. At our Wentzville location, we've embarked on a transformative journey to optimize the production line for our Spec Air Series. Let's explore how adopting a model line approach has not only boosted efficiency but also enhanced the quality of our offerings for our valued customers.

Motivation for Standardization:
Our decision to implement a model line approach was fueled by a shared commitment to eliminate uncertainties in our production process. Inspired by the success of the Toyota method, we aimed to establish complete standard work, leaving no room for ambiguity. Past challenges during new product rollouts underscored the need for a structured approach to ensure success.

The Four Cells Approach:
We divided the Spec Air Series production line into four specialized cells, each dedicated to a specific stage of manufacturing. This one-piece flow model streamlined transitions and increased efficiency, with a notable improvement being the integration of crate assembly into the testing phase.

Small Teams and New Product Line Advantage:
Introducing small teams into each cell facilitated smoother navigation of the challenges associated with a new product line. This setting allowed team members to set their own pace and significantly contribute to the project's success. Standardized instructions reduced confusion and empowered our team, resulting in increased morale and a reduction in quality issues.

Key Performance Indicators (KPIs):
Monitoring our success involves hands-on tracking of key performance indicators. A dedicated whiteboard in the shop meticulously tracks the time for each step of the production process, ensuring alignment with our goals and facilitating continuous improvement.

Impact on Morale and Quality:
With standardized work in place, team members are empowered to excel, leading to a noticeable drop in quality issues. The Spec Air Series production line achieved an impressive 99% quality rate, demonstrating the positive impact of our approach on both morale and product quality.

Striving for Continuous Improvement:
Our journey doesn't end with our current success. We're committed to constant evolution, always exploring better practices to enhance our production methods and deliver top-notch products to our customers.

The transformation of our Spec Air Series production line through a model line approach highlights the power of standardization and teamwork. By embracing specialized cells, small teams, and key performance indicators, we've successfully navigated the challenges of a new product line rollout, resulting in increased efficiency and a motivated workforce. Join us for a tour to see the Model Line in action and learn more about our commitment to excellence in production.