Metal products & Machinery

Integrated supply chain & manufacturing optimisation

BUSINESS CONTEXT

  • Producer and supplier of press fitting systems and pipes.
  • Capacity shortage because of strong volume growth.
  • Lack of self-engaged operational improvements.

CUSTOMER NEED

  • Improved delivery service & reduced inventory & cost.
  • More manufacturing output while maintaining high quality.
  • A sustainable operational improvement program.

RESULTS

  • Delivery service up 74%.
  • 35% inventory reduction.
  • 18-59% machine output increase for bottleneck areas.
  • 20% reduction of machine time needed, same demand.
  • Significant EBITDA improvement.

CHANGES

  • New leadership reviews to analyze process variances on service, throughput, due date.
  • IDEX: daily follow-up against production standards, changeovers and due dates.
  • Demand-based replenishment principles.
  • Reduced sourcing lead times.

R&G APPROACH

  • Initiated pull system in supply chain triggered by true customer request date.
  • Implemented Stable Operations & Demand Pulse.
  • Leadership coaching in the use of the operating system.

CLIENT TESTIMONIAL

“We changed the basis for decisions from opinions to facts.. The acceptance of change increased significantly and the management team focused much more quickly on the real problems!”

General Manager