Restructuring Production & Logistics in Heavy Gearbox ManufacturingTiancheng Machinery, Jiangyin China, Machinery & Equipment

Crafts: Flow Optimization
Service: Delivery Transitional Leadership
Project Date: October 21, 2021
Project_Tiancheng
Tiancheng Machinery operates both legacy and new production facilities, manufacturing precision gearboxes for diverse heavy-industry applications. The company faced bottlenecks in scheduling and material flows across facilities due to production complexity and space constraints.

Eddso conducted a dual-factory optimization program focusing on smart scheduling, plant layout re-engineering, and visual management. A tailored approach was adopted to improve internal logistics, reduce congestion, and streamline assembly workflows.

Challenge

Legacy and new plants lacked integration in scheduling and layout, leading to delays and inefficient flows.

  • Disconnected Production Islands
    Departments were physically distant with mismatched production rhythms.
  • Inefficient Floor Usage
    Legacy factory had low storage density and poor flow directionality.
  • No Unified Planning Tool
    Production planning relied on spreadsheets, lacking real-time adjustment capability.
  • Limited Visual Guidance
    Signage and workstation visibility were inadequate for coordination and oversight.

Solution

Eddso’s team implemented a comprehensive flow redesign and digital visualization strategy.

    • Factory Flow Re-engineering
      Redesigned plant layout using spaghetti flow analysis and lean zoning.
    • Dynamic Scheduling Board
      Built real-time planning boards to align machining and assembly slots.
    • Smart Storage & Supermarket Zones
      Introduced FIFO racks and route-based material handling systems.
    • Visual Management System
      Designed cross-functional visual guides including signage, safety zones, and logistics coding.

Milestone

STEP

Demand Alignment

STEP

Onsite Investigation

STEP

OpEx Solution

STEP

Implementation

Results

Tangible improvements in space utilization, scheduling stability, and visual transparency.

  • +15% Throughput Capacity
    Optimized floor use and synchronized shifts boosted output rates.
  • -30% Material Handling Time
    Shortened movement routes and congestion relief.
  • Real-time Planning Accuracy
    Live updates enabled quick adjustments to daily output plans.
  • Operator Empowerment
    Visual guides improved cross-line coordination and reduced task ambiguity.

How Plant Scheduling & Visual Management boost Gearbox Production?

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