Manufacturing Case Study

Portuguese cable products manufacturer

Poor management, poor planning and scheduling systems

Established a clear and visible planning process between sales, planning and production

Lack of an effective production Planning and Scheduling system
Poor management skills and capabilities
Lack of effective communications, particularly between sales and production planning
Wide product range / variety
Excessive levels of inventory
Poor quality of supervision within the factory

Defined and implemented an integrated planning and scheduling system
Trained management and staff in planning and scheduling methodology
Established integrated management review mechanisms
Established short interval control techniques within the factory
Improved the level and quality of shop floor supervision
Established an Action Team framework to address issues including: set-up procedures, maintenance, quality control, raw materials stock management
Carried out management training and development programme

Improved communications between sales, planning, production and support areas
Simplified maintenance procedures and reduced down-time
Improved operational control on a day-to-day basi
Improved team working
Achieved a major shift in attitudes and working relationships throughout the organisation
Established a clear and visible planning process between sales, planning and production
Improved quality of output
Increased outputs on key product lines
Reduced levels of inventory