Objective: Deeply transform itself to keep its customers

Context

A customized special-steel-made flat sheets manufacturer forced to deeply transform itself to keep its customers, notably regarding its level of service.

Approach

After a 8-week diagnosis and impetus phase, conduct of a transformation program axed on 7 improvement themes:

  • Flow management: PDP, planning and scheduling

  • Shipping logistics

  • Productivity: equipments "de-bottlenecking", heat treatment furnaces productivity

  • Flexibility: steel work optimization,  mill adaptability

  • Methods and quality departments organization, reduction of non-conformities

  • Customer service function (order monitoring, aftersales service,...)

  • Teams management and monitoring

 

Deliverables

  • Creation of the PDP tool and system

  • Design and implementation of a planning for the plant (structure, tool, range) based on the bottleneck availability

  • Re-organization of customers service, redesign of processes and tool for orders registration

  • Overhaul of the rules of casting sequence and campaign management

  • Setting up of a central cell for methods department

  • Maintenance restructuring

  • Creation of structures and management charts within the plants: executive committee organization, production meeting: 5' meeting, professionalization of the 1st level management

Results

  • Improvement of the critical equipments reliability (FMEA)

  • Reduction in causes of equipments failures (SMED)

  • Early detection of non-quality and work on root causes

  • Storing and reduction in finish products and raw materials inventories, improvement of the shipments preparation, transport optimization by daily commute

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About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean & ToC training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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