INDUSTRY: Medical Device
SERVICES: Crisis Management. Logistics. Operations.
Situation.
The client’s facility was working 24/7, experiencing a tremendous backlog, delayed shipments for a key customer. The Seraph team was engaged to improve operational efficiency, recover from the backlog of delayed shipments, improve capacity and reduce overtime.
ACTIONS.
Leadership & Process
- Restructured production organizational chart by introducing team leads and supervisors.
- Led in-cell associate skill development programs.
- Standardized shift handover procedures.
- Conducted leadership coaching and established regular leadership routines.
- Initiated a war room to foster a culture of timely, targeted actions.
Driving a Data-based Culture
- Deployed ProductionNet, a cloud-based solution for tracking production line performance.
Equipment Enhancement
Designed, developed, deployed and validated both tooling and equipment to:
- Decrease quality loss
- Improve productivity and cycle times
- Reduce equipment downtime
- Relieve bottlenecks to increase capacity
Result.
- Created value through quick reduction of scrap and labor costs, which increased capacity and revenue growth
- Realized annual labor savings of $780,000 ($15k weekly) through:
- Reducing workdays from 7 to 4, thereby cutting overtime and enhancing performance.
- Standardizing shift handovers, saving 1-2 hours per shift.
- Fostered a rapid-response culture and accountability through ProductionNet data and the War Room approach.
- Achieved over $780,000 ($15k weekly) in annual scrap savings due to quality enhancements.
- Identified and implemented a solution to a gap in oven capacity via capacity analysis, reducing cycle times and eliminating 80 minutes of non-value-added time per shift.
- Increased production capacity enabling the manufacturing of an additional 200 parts per week, unlocking an additional $4,914,000 ($94,500 weekly) in annual revenue.
