About

Manufacturing and instruments production facility with 250+ FTE. Project duration – 6 months.

Objectives

Business process optimization, costs optimization and headcount right sizing. Personal areas of assignment were production, quality control, sales and marketing, procurement, R&D.

Analysis Phase

Analyzed existing processes and procedures in Production department:

• Planning, forecasting, control and evaluation methods;
• Management behavior;
• On-floor practices – materials availability, man-load planning and allocation, WIP, QC;
• Market and Strategy analysis in Sales – competitors, dealers, communication approach, segmentation, etc.;
• R&D analysis from idea to production approval.

>> Activities – performed man loading, ratio delay, variance study, scrap control and management, flexibility matrix and responsibility charts, bottleneck analysis, value stream mapping, line balance, capacity analysis, detailed observations.

Design & Implementation

• Validated, justified and agreed process requirements, improvement potentials and action measures in all departments;
• Re-designed, tested and deployed resource Master Schedule, which was later integrated into existing ERP;
• Implemented management tools and routines to engage active supervision;
• Outsourced non-typical activities;
• Agreed and applied measures towards reactivation in Sales & Marketing;
• Deployed Poka Yoke approach at key production spots allowing operators to evaluate if produced conforms with requirements.