The Challenge:
The client, a world leader in production controls and automation, experienced rapid growth through economic expansion which strained the capacity of its global master depot operation which processed more than $3.0B in parts for the company annually. Following a troubled WMS implementation our firm was engaged to bring the master depot under control and optimize throughput and operating cost.
Results:
We conducted a detailed analysis of operations and led the organization through our structured steps to stabilize and improve performance quickly.
Highlights this client achieved:
- From 22% to 6.0% in overtime cost.
- Increased daily line capacity 15-20%.
- Provided leadership development for new management team.
- Classroom education on distribution operations management.
- Orchestrated more than 15 engineering projects to change the flow, layout, processes, roles & responsibilities.
- Implemented rigorous and disciplined daily, weekly operating activities to hone execution and accountability to results.
- Restructured the organization as well as realigned the shift responsibilities to improve throughput and quality.
- Developed process level Key Performance Indicators and analytics to highlight gaps in the operation.
