Trane/Ingersoll Rand Combines Lean and Operations Research Tools to Redesign Feeder Manufacturing Operations

Trane U.S. Inc., a brand of Ingersoll Rand, is a leading global provider of indoor comfort systems and services. It provides service, parts, and financial solutions to commercial and residential customers worldwide. In this paper, we showcase results of combining classic lean techniques, such as value stream mapping, with operations research analytics, including statistical and simulation modeling, to dramatically improve the manufacturing of a problematic feeder component assigned to a dedicated manufacturing process. We first used value stream mapping to visualize the process and develop an overall lean strategy for the manufacturing cell. We then used regression analysis to express the relationship between numerous product attributes and improvement opportunities. Finally, we developed simulation models to assess the effectiveness of process changes on cell performance under a wide range of demand and processing conditions prevalent at the plant. Process improvement recommendations presented to Trane management included (1) a redesigned material strategy, (2) a new cell layout, and (3) a one-piece product flow. In combination, these improvements facilitate a 13 percent throughput improvement, 50 percent cycle-time reduction, and higher cell efficiency that led to projected recurring savings of more than $700,000 per year.