The context is a manufacturing process of high performance alloys mainly for the aerospace industry.
Low productivity on the shop floor, poor planning & scheduling practices and the lack a robust Sales & Operations Planning (S&OP) process caused accumulated delays, resulting in a significant decrease in new orders and profitability.
Critical operating management tools were not in place. Sales department needed a new set of management tools to drive increase in volume and margin.
Operational Excellence to achieve new levels of performance in productivity and profitability
SALES & OPERATIONS PLANNING (S&OP)
The implementation of a streamlined planning & scheduling process kept production in line with budget objectives.
The alignment and synchronization across departments leaded to an increase in productivity and profitability.
The implementation of the new process enabled to order the right raw materials at the right moment and at lower costs.
Development of Sales Management Operating System to support the process of obtaining new orders & increase margin.
OPERATIONAL EXCELLENCE
Structured and effective weekly performance meetings created a team environment, giving all departments a forum to share valuable information and break silos.
Production line workers increased efficiency as a result of short interval control added to the workflow.
Implementation of visual management across the shop floor to capture production deviations and display KPIs.
Reviewed and streamlined organizational structure along with clarification of roles and responsibilities clarified to align deliverables across departments.
MAINTENANCE EXCELLENCE
Reviewed and streamlined organizational structure along with clarification of roles and responsibilities clarified to align deliverables across departments.
90% increase of preventive maintenance operations.