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Magnys > Bluebird

Reduced assembly manhours by 56% saving us $55 million over ten years


56% Savings

After negotiations to purchase a chassis from a supplier fell through Bluebird Bus Co. decided to design and manufacture their own. Bluebird estimated they could reduce the number of man-hours required to build the chassis by 18% and approached Magnys Innovative Solutions to review their plan. Magnys helped Bluebird determine how to optimize manpower, automation and costs to achieve their goals and go beyond. We  produced an optimal layout, developed the assembly process and compiled the operator work instructions (linescroll).

The new combined chassis assembly facility reduced assembly man-hours by 56%, reduced repair time per vehicle from eight hours to nearly zero and saved Bluebird $55 million in labor costs over a ten year period.