A key production site of a major equipment manufacturer was facing a severe production crisis (4 months of delay at the start of serial production) : poor program management, poor industrialisation robustness, poor production process capability, lack of performance monitoring system, lack of supply chain & procurement strategy (100% of single source suppliers, lack of rate readiness assessment)…

Approach

> Set up of a strong management team on shop floor with KPIs and performance monitoring tools to contain the crisis in the short term

> Definition and implementation of a recovery plan by reviewing key operational organizations and processes around 4 streams

1.Configuration management : definition and set up of a change introduction process

2.Supply chain monitoring : creation of a supplier monitoring plateau, definition of a robust management system of raw materials ordering, support of critical suppliers

3.Production management : implementation of performance monitoring system, review of the entire performance monitoring system, review of the lay out, creation of rework cells,…

4.Quality : Implementation of quality wall and feedback loops

Results

> Production rate multiplied by 3 in 8 months

> Reduction by 37% of the production lead-time of kits

> Reduction by 68% of the lead time due to non-quality