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Do you have any of these problems

  • Disjointed and dysfunctional manufacturing flows

  • Erratic production schedules causing intermittent, start and stop flows and missed schedules

  • Excessive production floor paperwork and transactions

  • Excessive and unexpected downtime

  • Frequent shortages as well as excess inventory

  • Capacity problems and surprise production bottlenecks

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%

  • Work-in-process inventory reduced by 78%

  • Manufacturing cycle time reduced by 40 - 60%

  • Production floor paperwork and transactions reduced by 75%

  • Demonstrated capacity increased by 15%

  • Unplanned downtime reduced by 50%

  • Setup/changeovers reduced by 25% without additional working capital

  • Productivity increased - units per person - by 35% 

  • Improved line balance and material flow which reduced bottlenecks by 75%

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

  • 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.    

  • Improved material planning and releasing methods for long lead time components.  

  • Focused setup time reduction programs to increase plant flexibility, reduce production intervals, create better flow across the value-stream.  

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

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

 

Articles

  • Gaining a Competitive Advantage with Synchronous Flow Manufacturing

  • Japanese Style Execution vs. American Style Planning!

  • Consider These Questions Before Changing the Master Production Schedule

  • Class A Regained at Dade Behring

  • Getting Started With Sales and Operations Planning

  • Making More With Less Is Lean Manufacturing

  • Are You Really Ready for Lean Manufacturing?

  • Master It (Master Scheduling and Lean Production)

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)