PRODUCTION SYSTEM IMPROVEMENT AND RELIABILITY OF A 4000 PEOPLE INDUSTRIAL PLANT

A major production site (~4000 FTEs) of an OEM was facing its 2nd recovery plan in a row to meet its production targets in a context of a ramp up.
Maexinvent was hired to set the basis for a robust and sustainable production system to secure continuous ramp up of the program and avoid an additional costly recovery plans.

Approach

> Assessment of operations and management systems as well as mindset and behaviours of all functions from engineering, to planning, to quality, to production

> Co-definition with the client teams of a comprehensive “production oriented” solution build around 4 main streams :

1.Production : re-empowerment of production teams on their activity through creation of multifunctional teams ; review of industrial set up of the hangars ; definition of a robust outstanding work management system

2.Planning : strengthening of Master Production Schedule system to cope with reality and ensure alignment of suppliers

3.Supply chain & Logistics : improvement of incoming quality, re-definition (organization & processes) of logistics organization in hangars

4.Quality : redefinition of quality organization to reduce NC management and concessions lead-time and improve quality check on shop-floor

> Implementation of solutions by immersing our teams in operational teams, taking part to operational meetings and supporting decision making at site level

Results

> End of backlog creation – No need of a recovery plan to fulfil production target by end of the year

> Reduction of volume of outstanding work by 25%

> Final quality gate improved durably by + 40 pts