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The context
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Electrical accessories company witnessing 50% drop in Sales, high quality complaints with market returns at 14% of Sales
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Production planning focused on capacity utilization and batch processing, with more than half of customer orders not being fulfilled
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Low employee morale, high inventory of 8 months and cash losses
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THE SOLUTION
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Lean Manufacturing initiative with multiple process streamlining and team performance optimization waves deployed
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Manufacturing and Sales teams trained on Waste identification and elimination
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SKU changeover times shortened, and assembly cycle times reduced through single piece flow
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THE IMPACT
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SKU changeover times shortened, and assembly cycle times reduced through single piece flow thereby improving productivity and reducing standard costs
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Market returns reduced to 3% with delivery performance at 92%, and finished goods inventory of only 3 weeks
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Attrition rates radically brought down from 70% to 20%