Process Improvement

Manufacturing client was losing competitive advantage in their marketplace. Customers were unsatisfied with product price and lead-time. Premature launch of new MRP system created chaos throughout the demand-to-ship process. Inventory was excessive. A process improvement initiative was needed to reduce costs and improve deliveries.

Outlined improvement goals to reduce costs by 10%, improve on-time delivery to 95% and reduce inventory by 10%. Performed Manufacturing Process Evaluation, Analysis and Redesign (PEAR), including process mapping and integration, inventory analysis, lean manufacturing, yield analysis, kaizen metrics planning, product launch process, visual management and capacity improvement planning. Goals were achieved.