Customer examples: accelerate operations
Lean supply chain for greater flexibility & lower costs
Challenge
- Help a major international manufacturer to define and implement a comprehensive outsourcing strategy with a selected partner, based on agreed way of working
Where we helped
- Identification of value-add per activity
- Assessment of labor suppliers, and trade-offs between component and activity outsourcing
- Development of seamless, integrated way of working
- Cultural change and transformation from purchasing to supply management
Result
- 10% cost reduction and higher customer satisfaction
Optimization from sales to order fulfillment
Challenge
- Improve end-to-end sales to order fulfillment performance for a global home electronics manufacturer, including setting up a completely new supply chain
Where we helped
- Improved forecasting accuracy from 25% to 49% in 3 months
- Reduction of inventory by 75% in 4 months
- Creation and testing of ERP and warehouse management systems
- Design of new ways of working; hiring and training new staff
Result
- A new, efficient supply chain, with high performance Sales & Operations
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Lean transforms factory performance
Challenge
- Improve the operational excellence of a major manufacturing site
Where we helped
- Introduced lean practices in close cooperation with management and shop floor
- Intensive training for management to be self-sufficient in lean
- Establishment of “kaizen” teams on shop floor
- Entire new factory hall built based on lean principles
Result
- Gains of 20-30% in production efficiency, 40% in stock reduction, and 35% in factory throughput
