Situation

The client was a manufacturer of custom cabinets. We were engaged to assess potential opportunities to optimize productivity.  In general, the client and senior management valued the concept of continuous improvement.

Requirements

Schroeder & Schroeder was commissioned to determine the operations optimization potential by:

  • Capturing and documenting key performance factor audit results
  • Capturing and documenting waste analysis observations and results
  • Documenting key challenges, priorities and recommend opportunities to increase profits and reduce waste

Challenges

The main challenges faced on this project included:

  • How to manage and maintain a realistic production schedule across the organization that can meet promised delivery dates
  • How to manage and track raw materials, work-in-progress and finished goods effectively
  • Excess inventory taking up space in the manufacturing facility.

Actions

After analyzing the organization, our consultants addressed the challenges presented and performed the following actions to deliver results to the client. Key activities included:

  • Drafting initial productivity potential report; capturing and documenting the client’s top 3 expectations
  • Meeting with key personnel, captured and documented information on external and internal factors
  • Business Process Mapping and conducting root cause analysis using Ishikawa Diagram
  • Capturing and documenting key performance factor audit results
  • Capturing and documenting waste analysis observations and results
  • Documenting key challenges, priorities and recommend opportunities to increase profits and reduce waste

Results

Through this approach, Schroeder & Schroeder developed a comprehensive operations optimization plan. At the end of our final presentation, the client confirmed that they were prepared to move forward with the recommendations and timeline proposed.