Ace Designers Case Analysis Questions:

2. What were the main challenges that Macha and his task force faced while designing and
implementing half-day indexing? How did he overcome these challenges?

Main Challenges in Half Day Indexing

A) How to change the product design to reduce the effort required without comprising Quality
or Customer needs?

B) Infrastructure improvements in the floor to reduce lead-time and manual effort.

C) Rejection of half day indexing by the operators.

Overcoming Challenges

A) Addition of indicative slots on the machine frame and metal cover. These slots would clearly
mark where an operator had to place a screw and tighten it, earlier operators used to spend up
to 10 minutes locating the spot using precision measurement tools.

Smooth drilled holes for screws were converted to tap holes which improved the control and
efficiency of the process.

Re-designing of sheet metal parts

B) Designed a new trolley and rail system that could be used across different product lines and
eliminated the need to move the machine during testing.

C) Macha decided to assemble a machine by himself and demonstrate it to the workers. After
the successful assembly of a machine all by himself, he invited the operators to do it with him.
The workers were not given any additional work if they finished the activities at a workstation
before four hours.