Projects
Lean Management, Optimization of Operations
Context
Our client employing 50 people with a turnover of €10.5 million in 2022, aimed to optimize its supply chain and implement lean fundamentals to enhance operational excellence. The primary issues included internal non-quality recorded through non-conformity tickets, inefficient planning processes requiring a lot of manual tasks, and a need to implement forecasting processes.
Objectives
Qualitative:
Increase customer satisfaction
Reduce non-quality issues and costs
Improve operations planning
Reduce inventory
Digitize operations
Analysis of Non-Conformity Tickets:
Characterized quality issues and identified root causes.
246 tickets analyzed, with 66% of problems concentrated on 9 specific issues.
Defined an action plan to reduce the current problems.
Planning Processes:
Formalized the current process and identified the main issues.
Proposed an action plan to digitize and optimize the process.
Inventory Management and Forecasting:
Reviewed and optimized the forecasting and safety stock calculation processes.
Our Recommendations
Implementation of a Dashboard to monitor non-conformities.
Semi-Annual Follow-Up and Analysis of Non-Conformity Tickets to continuously improve quality.
Establish a quality governance system to oversee and manage quality-related processes.
Implementation of specific action plans to solve identified problems.
Our Solutions
Expected Deliverables:
Dashboard for non-conformity monitoring
Report on root cause analysis for non-conformities
Optimized and formalized planning and forecasting procedures
Semi-annual analysis report
Benefits
Expected Performance Gains (Before vs. After Dillygence Intervention):
Before:
The pragmatic forecasting method used to manage component supply had not been qualified and risked generating overstocks and/or shortages.
After:
The forecasting method was validated through its comparison with a best-in-class method, confirming its short-term application.
The implementation of the best-in-class method presents a challenge in reducing stock coverage by more than a month but requires an evolution of the information system.