Case study REF#16
THE CHALLENGE
Drive productivity improvements during rapid growth
Rapid growth meant that the continuing success of the client’s strategy depended on improving multiple facets of the company’s operations simultaneously while significantly improving margins, cycle times, and product quality assurance.
OUR FINDINGS
Identified five items for improvement
- Poor planning and scheduling affecting the organization’s ability to meet customer commitments
- Significant opportunity to improve margin contribution from core products
- Opportunities across all production lines for cycle-time reductions
- High internal cost of poor quality
- Multiple locations with standardized processes had created “local” process workarounds driving inefficiencies across the value stream
IMPLEMENTATION
We focused on 5 areas of impact
Established a basic EHS management system to drive safety behaviors.
Implemented processes and systems to track and manage safety observations/actions.
Improved safety programs to drive employee participation.
Installed a work management process and a production loss accounting system.
Implemented a material and production scheduling process.
Installed short interval controls on key production parameters to ensure each shift operated in a similar manner.
Implemented improved planning and scheduling processes to drive efficiency.
Completed equipment RCAs (Root Cause Analysis) and FMEAs (Failure Mode and Effects Analysis) to improve the reliability of bad actors and critical equipment.
Developed an organizational structure, including roles & responsibilities with clear accountabilities and lines of reporting.
Implemented a new scheduling process to leverage correct product sequencing and campaign lengths.
Integrated inventory management into the scheduling process to reduce obsolete inventory.
RESULTS
All delivered with a 3:1 Return on Investment
It was incredibly difficult when we first started, trying to get the leadership team and the organization as a whole on the same page, but we did persevere thanks to the efforts of your team and the time and effort you spent working on the shop floor…which funnily enough is exactly what you promised.
Global Procurement Director
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