The production of automotive ignition coils in Brazil is presented as a case study of lean manufacturing. The evolution of the project from initial concept to the implemented process is shown. The savings realized by utilizing lean manufacturing techniques are presented by comparing the initial concept to the final process. Metrics utilized include: Investment, floor space, and labor. The metric of equipment “value” (speed/cost) is also introduced as a method of measuring the impact of lean manufacturing. Additionally, other factors that impacted the success of the project are discussed.
