A study was conducted at the sole global producer of suspension struts for a particular vehicle manufacturer. This supplier is currently able to meet customer demand. However, it does so because of a large finished goods and work-in-progress (WIP) inventory. The plant operates two production processes that are separated by a large buffer of WIP, which essentially decouples the production processes. This study aimed to reduce this WIP buffer; this would require the processes to become synchronised, bearing in mind that the reliability of delivery should not decrease. A tool that considers time, quality, and machine capacity was developed to assess the impact of line synchronisation on company performance figures. It was found that line synchronisation produced several benefits for the supplier, including batch size reduction, lower inventory levels, and associated shorter lead times. This further allowed the supplier to improve flow in the plant by introducing a pull system. Improved visual oversight could lead to further improved problem-solving and innovation. OPSOMMINGʼn Gevallestudie is by die alleenverskaffer van suspensiestutte vir ʼn spesifieke motorvervaardiger geloods. Die vervaardiger kan tans die vraag van die kliënt bevredig, maar dit is as gevolg van ʼn groot voorraad van voltooide goedere en werkstukke in proses. Die fabriek bedryf twee vervaardigingsprosesse wat met ʼn groot buffer van werkstukke in proses geskei word. Dit ontkoppel effektief die produksieprosesse. Die doel van hierdie studie is om die werk-inproses buffer te verminder. Dit vereis dat die prosesse gesinkroniseer moet word sonder dat die betroubaarheid verminder word. ʼn Gereedskapstuk wat die tyd, gehalte en masjienkapasiteit in ag neem is ontwikkel om die impak van produksielyn sinkronisering op die maatskappy se vertoning te bepaal. Daar is gevind dat die produksielyn sinkronisering verskeie voordele vir die verskaffer inhou, onder andere vermindering van lotgrootte, laer voorraadvlakke en korter leitye. Dit het die verskaffer toegelaat om die vloei in die fabriek te verbeter deur ʼn trekstelsel bekend te stel. Verbeterde opsig kan lei tot verder verbeterde probleemoplossing en innovasie.

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