Main content

Do you have any of these problems

  • Poor manufacturing on-time delivery performance

  • Poor supplier on-time delivery performance

  • Last-minute production surprises

  • Excessive lead times

  • Inflexible plant schedules

  • Inflexible manufacturing processes

  • Inflexible suppliers

  • Push scheduling system causing excessive WIP and missed schedules

Learn the secrets to getting these kinds of results (results are from our clients):  

  • MPS performance up 57 percentage points

  • Master schedule on-time performance consistently above 95%

  • Manufacturing cycle time reduced 50% or more on all lines

  • Work-in-process inventory reduced by 78%

  • Demonstrated capacity increased by 15%

  • Productivity increased - units per person - by 35%

  • Supplier performance improved to over 95%

 

Typically our clients have worked on the following areas to show the kinds of improvements listed above:  

  • Upgraded sales and operations planning processes to ensure resources - key materials, people and equipment - are available at the right time to execute a lean strategy.  

  • Better master scheduling and leveling techniques to achieve production stability.  

  • Improved scheduling mechanisms including load leveling boxes to communicate finishing schedules to the key pacemaker processes.  

  • New lean strategies for producing to customer orders or to finished good supermarket replenishment signals rather than to forecasted demand.    

  • Focused setup time reduction programs to increase plant flexibility and reduced production intervals.  

  • Improved statistical process controls and other quality techniques to reduce variability and eliminate scrap.  

  • Implemented supplier scheduling processes to give advanced visibility of purchasing requirements for key materials.  

  • Developed vendor managed inventory methods to reduce duplicated efforts and streamline purchasing activities on certain classes of material.  

 

You can find additional information about these problems and their solutions here at this website in the following places: 

 

Articles

  • Coca Cola: "Always" Class A MRP II

  • Consider These Questions Before Changing the Master Production Schedule

  • Class A at DuPont Polyester Films

  • Does Your Supply Chain Measure Up? 

  • Class A Regained at Dade Behring

  • Value/Supply Chain Management - Where Do You Start

Tailored classes and workshops

  • A solid, well-planned program of tailored, on-site education

  • Tailored education methodology

Consulting and assessment

  • Objective assessment of strengths, weaknesses, and opportunities for improvement

  • Tangible improvements and financial results as you go

 

You can get personalized help.  If you would like to discuss your company's situation in more detail, you can send a question or comments to one of our Senior Partners using the form below, or you can call directly. 

 

John Dougherty (1 603 528-0840)

Chris Gray (1 603 778-9211)

Don Rice (1 615 221-2196)