Case studies

  • RETEX OF AN INSTALLATION

    • A player in the energy industry was unable to deliver to its customers on time.

    To address this issue, we have set up a complete Lean organization via an 8-month project, based on three major levers:

    1. A unique production sequence
    2. Control of outstandings via online publication
    3. A redesign of the role of managers

  • OBSERVATIONS

    • 4 different schedules in the factory
    • 10 products started 3 in progress
    • No vision of the work done and what remains to be done

     

     

     

     

  • CONSEQUENCES

    • 50% of the plant shut down
    • €1,200k in late payment penalties
    • Frustrated staff working overtime to catch up

     

     

     

     

  • SOLUTIONS

    • 1 single schedule for the whole plant
    • 3 products online and in progress
    • Advance/delay visible to all
    • Material anticipation routine
    • Emergency reaction circuits set up with the support teams

  • RESULTS

    • Encrypted

     

     

    • Reduction of Lead Time by 20 days, or 60%
    • 100% parts delivered on time
    • 0 additional hours
    • 60% reduction in work in progress

     

     

    Humans
    • Operators “There is no more urgency, and we know what to produce.” ; "We no longer need to move tools, machines,..." ;"It's much less tiring and more pleasant."
    • Supervisor “In addition to the results, the project has created a real team spirit between all of us: operators, management and support functions.”
    • Plant Manager “Well done! Now we know how to deliver our customers on time. And I am particularly proud to see the evolution of the teams, the mutual support and all that you have learned during this project."