A medical products manufacturer known for its infusion therapy and pain management solutions, faced critical labor and assembly line complications that went unaddressed. Leadership first noticed declines in labor productivity for the low frequency medical products made in a clean room environment. At the same time, product families that should have been grouped together on work cells were done independently, resulting in imbalanced processes with many bottlenecks. Adonis Partners was brought in to implement a line balance process for optimized labor productivity and a control plan to sustain improvements.

Adonis’ expert consultants began by identifying key product families, conducting time studies, and mapping out each task along the production line. Working side by side with operators, consultants directed a non-value added (NVA) waste identification and elimination project. Once all improvements were identified, a standardized line balanced workflow was established and employees learned the refined process. To ensure continuous improvement, a monitoring and sustainment plan went into effect.

In just 4 months, the client saw a remarkable 30% increase in labor productivity and over 180 SKUs analyzed for improvement. Adonis’ work set the bar for efficiency at a new high and prepared the production department for long term growth.