Our Continuous Production Optimization: Shorter Lead Times and Tighter Quality Control through Lean Management and Advanced Technology Implementation

At ORA Engineering, our commitment to improvement is embedded in everything we do. In 2023, we began an intensive production optimization process guided by lean manufacturing principles, and this effort is far from over. Our culture of constant self-optimization drives us to continually refine our processes, ensuring that we enhance both efficiency and quality. In this article, we’ll give you a closer look at the technical innovations and management strategies that make this possible, offering insights into how we maintain reliable, watertight quality control at every stage of production. Our goal is to ensure that every order, no matter how urgent, meets the highest standards of craftsmanship and reliability.

Lean Manufacturing: Streamlining for Faster, More Efficient Production

At the heart of ORA Engineering’s production optimization is our commitment to Lean Manufacturing principles. Since 2023, we began analyzing our entire production line using value stream mapping and work-study analysis. This process allowed us to identify and eliminate bottlenecks that were slowing down production and optimize our workflows for better efficiency.

For those who aren’t familiar with production management, Lean Manufacturing is all about making processes more efficient by reducing waste. Waste can be anything that doesn’t directly add value to the final product—like extra time, unnecessary movement, or using more materials than needed. The goal of Lean is to streamline each step in production so that everything runs smoothly and efficiently, with fewer delays or wasted resources.

At ORA, we applied Lean Manufacturing by examining every aspect of our operations — from raw material intake to final product assembly. We identified inefficiencies and worked to reduce wasted time and effort. Below is a few examples of bottlenecks we found during the process and what we planned to do to eliminate them: 

Table 1: Bottlenecks and implementation plan from ORA Engineering’s Lean Manufacturing Process

The results of our Lean Manufacturing improvements have been significant. Here are two examples to give you a better understanding how we did it: 

Tube Mold Management and Storage Optimization:

• Initially, we faced inefficiencies with over 800 molds, which required manual searching during tube extraction.
• By organizing the molds using the 2S method (sort and straighten) and identifying the top 100 frequently used molds with a Pareto Chart, we drastically reduced retrieval time.

Results:

• Molds weighing over 10 kg were placed at an ergonomic height, allowing staff to change molds without bending, reducing strain.
• Frequently used molds were grouped together on the same rack, reducing walking steps from 30 steps to 10 steps per batch, saving operators from 100-160 steps daily and improving workflow efficiency.

Small Batch Transport Cart Implementation:

• Previously, transporting batches of 20 frames between workstations took 10-15 minutes and required two operators.
• We introduced a smaller, mobile cart that holds 6 frames and can be managed by a single operator.

Results:

• Transport time was reduced from 10-15 minutes to 5-8 minutes.
• The cart now only needs one operator, increasing efficiency and freeing up resources.
• Instead of waiting 4 hours to complete a batch of 20 frames, we can now move smaller batches to the next station every hour, significantly speeding up the entire production process.

These adjustments have optimized our production line, reducing inefficiencies in material handling and transport. As a result, we’ve been able to reduce lead times by 20%, ensuring faster deliveries without any compromise in quality.

State-of-the-Art Equipment Enhancing Precision and Quality Control

Alongside our lean manufacturing practices, ORA Engineering has invested in advanced technology to further improve the precision and efficiency of our production process. We recently introduced two key systems: the AI-assisted Internal Tube Inspection System and the Multisensor Measurement System. These innovations have greatly enhanced our ability to monitor and control product quality, ensuring consistent results across the board.

The AI-assisted Internal Tube Inspection System has brought our quality control to new levels of precision. In the past, our team relied on manual visual inspections, which, over time, could lead to missed defects due to human fatigue. With this new system, we’ve trained AI models to identify and classify defects using image detection. It can now quickly and accurately detect imperfections inside titanium tubes—imperfections that are invisible to the human eye. This non-invasive system enables rapid, reliable inspections while maintaining full traceability of all data, significantly improving overall product reliability.

Real-time AI-Assisted Defect Detection: Watch as the yellow boxes appear on the screen, highlighting typical defects detected inside the tube.

The Multisensor Measurement System enables us to capture real-time data on product dimensions with pinpoint accuracy. This ensures any deviations are caught immediately, reducing the need for rework and minimizing downtime. This system is especially critical for custom parts, where compatibility with other components is crucial. By removing human error from the measurement process, we’ve increased the consistency of our output. For example, the inspection time for key components like cranksets has dropped from 25 minutes to just 5 minutes. Additionally, all measurement data is automatically uploaded to our MES system, providing real-time access and seamless integration into our production workflow.

Reducing Lead Times Without Sacrificing Quality

The combination of lean management and advanced equipment has allowed us to significantly reduce our lead times. In the past, a typical order required three months of production, plus an additional month for development. Today, we’ve shortened the development phase to just two weeks and cut production time to two months — all while maintaining our high standards of quality.

Flexibility for Urgent Orders with Our Fast-Track Channel

Understanding that some of you may have urgent needs, ORA Engineering has developed a Fast Track Channel. This option is designed for customers who require expedited production, allowing them to engage with us in an open discussion about their timeline and specific requirements.

By leveraging our optimized production processes and advanced inspection tools, we can confidently take on urgent orders without compromising on quality. The Fast Track Channel is just another way we stay true to our core values of being Original, Reliable, and Advanced, ensuring that even in the most demanding situations, we deliver superior results. 

Thank you for reading our deep dive into ORA Engineering’s production optimization efforts. This is our first technical article discussing the specifics of our manufacturing processes, and we’d love to hear your thoughts. Did you find this information valuable? Do you know someone who could benefit from learning about our innovations? Please feel free to share this article, and let us know if you’d like to see more content like this in the future!