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Project : Needs Analysis & Lean Phase 1
Client : Multinational German metal products company
Objective: Identify and recommend improvement opportunities and priorities for the company towards achieving better lead time, delivery performance, productivity, customer satisfaction and overall lean performance of the business
Scope : Cover multiple functions across the business - Sales & Marketing, Design & Engineering, Purchasing, Planning, Production, Quality, Maintenance, and Logistics
Duration : Total 35 working days : 10 days for Business Assessment, 25 days for Lean Phase 1 implementation.
Method : Apply ACTZEL's proprietary business process diagnosis tools, process mapping, value stream mapping, and priority matrix.
Outcome : Identified and prioritised 50 improvement recommendations that were arrived at after consultation with client management. Forty of these recommendations were for client management to action. The remaining 10 recommendations were for the development of organisational culture and implementation of Lean which required ACTZEL consultant to facilitate over an 18 month period. The Lean implementation was divided into 3 phases, namely basic, intermediate and advanced. As of writing this , phase 1 consisting of sustained Workplace Organisation system and Quick Changeover has been completed successfully. In parallel with phase 1 Lean, ACTZEL conducted a comprehensive Culture & People development programme for 50 key client personnel over a 2 month period.
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Project : Product Cost Model
Client : Multinational German metal products company
Objective: Product costing method to reflect actual cost
Scope : Non-standard customised product (Specials)
Duration: 10 working days
Method : Worked with Finance manager and Industrial Engineers to identify weaknesses in the costing model, determine the effect of various methods of apportioning cost across product lines, determine process cycle times and present different apportioning options and their effect.
Outcome : Presented to management the different apportioning options available and their effect to product cost. Coached the industrial engineers on synthesis time study method for customised products. Facilitated the preparation of action plan to complete the time study and incorporate it into the costing system and into the capacity analysis software. Established the cost drivers and improvement priorities. Provided Finance department with a way to cost the product more accurately than before.
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Project : Reduce Lead Time - Design to Delivery
Client : Multinational German metal products company
Objective: Recommend improvement for process from design to delivery
Scope : Non-standard customised product (Specials)
Duration: 10 working days
Method : Facilitate a cross functional team to map the current process from design to delivery, analyse the process for waste, brainstorm for ideas, filter and prioritise the ideas, and draw a future state map with action plan.
Outcome : Recommended an agreed plan to reduce the lead time by 2 weeks (from 8 weeks to 6 weeks).
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Project : Automate Production Planning
Client : Multinational German metal products company
Objective: Analyse and recommend measures to improve and automate the Production Planning process
Scope : Non-standard customised product (Specials)
Duration: 10 working days
Method : Facilitate a cross functional team to map the current production planning process from finished design to production start, analyse the process for waste, establish decision criterion, study suitability for automation, brainstorm for ideas, filter and prioritise the ideas, draw a future state map with action plan, and form a project implementation team.
Outcome : Recommended an agreed plan to automate a major part of the production planning process, minimise human intervention, and established a cross functional team with sponsor, leader, IT support, and core team members to carry the plan to completion.
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Project : Capacity Analysis
Client : US Aluminium Casting company manufacturing engine components based in South Australia
Objective: Identify measures required to help the client meet production targets
Scope : Production of Cast Aluminium Air Intake Manifold
Duration: 10 working days
Method : Conduct time study, establish takt time, determine improvement measures, and quantify the effect of each countermeasure on the ability to meet production output target.
Outcome : Visual presentation to the CEO of the production bottleneck, options for clearing the bottleneck and what effect each option would make to the production capacity. This provided the CEO with the facts needed to decide on appropriate actions required to meet production targets. The presentation was commended for its thoroughness, clarity and professionalism.
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