Case study · Metal fabrication · United States
What a steel fabrication plant changed in its first weeks
A steel fabrication plant needs to roughly triple its output. Cobalt set up cameras in 3 days. Two weeks later, the plant started changing how it works.
- to set up the cameras
- 3 days
- to first results
- 2 weeks
- changes made on the floor
- 8
- expected throughput, all changes together
- +40%
“After the first results, I was able to go straight out and change three or four things.”
What Cobalt delivered
- Time per unit, units finished and where the time goes, for every weld cell
- The bottleneck, and what is causing it
- Recommended process changes, each with its expected impact on throughput. Together: about 40% more
- Step-by-step instructions with pictures, written from the video (drafts delivered)
What the plant changed
Two weld stations made the same
Standardized the weekend after the first results, to cut wasted movement.
People moved between stations
The video showed which weld stations were fastest. People moved between them, and training went where it was needed.
No new hires
The data showed the plant already has the people it needs. The plan is to use their time better.
New safety gear for welders
The video showed an unsafe habit that was common across stations. The plant held a floor meeting and chose new eye protection.
A welding supply change
Switched a welding supply to speed up the weld cells.
Summer shift hours
Moved shift times in the summer months.
Layout decisions tested first
Layout options are tested in a simulation of the plant before anything is moved.
Improvement projects backed by data
Each project is now justified with measured numbers, not estimates.
Next
- The instructions posted at every weld cell
- New robot welders judged against the measured baseline
“It's accurate. Dead-on accurate.”
“Instead of wandering the floor, I can go straight to where I need to spend my time.”
“This is going to make running the plant easy.”