High Volume Discreet Part Manufacturer
Over the previous years there were several attempts to deal with the situation. Ultimately none proved to be successful as the client was busy dealing with increased sales, new products, customers and suppliers and trying to locally optimize with their specific situations. Staffing was, lean. Attempts to deal with the global situation never got off the ground or past the data collection phase. Data that was collected was primarily local and analysis methodologies, though similar, were influenced by functional silos. Over the previous years there were several attempts to deal with the situation. Ultimately none proved to be successful as the client was busy dealing with increased sales, new products, customers and suppliers and trying to locally optimize with their specific situations. Staffing was, lean. Attempts to deal with the global situation never got off the ground or past the data collection phase. Data that was collected was primarily local and analysis methodologies, though similar, were influenced by functional silos.
We were given the opportunity to assist our client in a “reset” that would take into account the complexity of the supply chain routings given the current asset structure and costs of rationalizations with respect to upcoming strategic and customer programs. We were able to work with an appropriate international, cross-functional team but had to respect their current time demands. Under the scope of the assignment and auspices of the corporate leader we constructed a program the included:
- Specific charter
- Team selection
- Onboarding
- Formatted data requests
- Verification of readiness of the team to proceed
- Group workshop to depict the current state
- Assignments to clarify and conduct in depth financial and operational reviews
- Approval of current state and verification of team readiness to proceed
- Group workshop to depict the future alternative states
- Assignments to add operational, investment and financial details to the alternatives
- Verification of team readiness to proceed
- Group workshop to evaluate alternatives utilizing
- Cause & Effect and FMEA methodologies
- Conduct Pugh Concept Development for unrecognized hybrid solutions and re-evaluation
- Solution selection and communication plan
Final recommendations, management presentations, justifications and ultimate overall implementation project management was conducted by the client.
End result: Lead time and cost targets were met.
Some highlights.
Group sessions were held at corporate headquarters and at select international sites where personal visualizations were beneficial.
Process sequence
High level Current State Map utilizing Lean Value Stream Mapping and Muther SLP techniques.
Detail flows for breakout discussions.
Simplified Current State VSM utilizing Muther SLP constructs
A Simplified Future State for Scenario Development
If you would like to request a listening session for your business, you can contact me, Bob Jeske, by email at bjeske@sbtimail.com.
