Client Case Studies

Case Studies: 1 to 5 (of 5)
  1 | 2 | | |  

Client:

Applied Kilovolts

Location:

United Kingdom

Contact Title:

Synatus Partner:

Andy Dobson

Assignment Type:


Interim management

Role:


Manufacturing / Operations

Discipline:

 

Sector:

Manufacturing

Challenge:

The Client needed to stabilise Operations, improve On Time Delivery (OTD) and recover staff morale.

Solution:

Andy turned around the business following periods of poor performance and the departure of previous post holders (twice!). He drove output through focusing on bottleneck(s) and process Failure Mode Analysis(FMA). Andy reviewed and re-configured the Enterprise Requirements Planning (ERP) system from 1st principles: He rewrote Bill of Materials (BOMs), timings, structures, phantoms, backflushes etc. and went on to train staff in the day to day maintenance of the system, re-organising roles, recruiting staff, auditing and consolidating sub-contractors. Andy instigated visual management to track products through the factory; he worked with sub-contractors to streamline order flow and deliver product in time with main production. He adopted a customer facing position with its largest clients, resolving supply issues and working directly with the biggest client to ensure deliveries to schedule. He also coached key stakeholders in basic Lean techniques; Visual Management, 7-Wastes, Right-First-Time, Flow and TOC.

Results:

"We used to struggle to get £240k/month out the door, we've just done £375k and we are asking when we will do £400k!" - M.D. Applied Kilovolts.


Client:

Glaxo Smith Kline

Location:

United Kingdom

Contact Title:

Synatus Partner:

Andy Dobson

Assignment Type:


Consulting

Role:


Discipline:

Business Transformation

 

Sector:

Pharmaceutical

Challenge:

Operational Excellence within Production Procurement in order to deal with issues around quality and capacity. The Director of Production Procurement tasked Interim Partners with hiring an Interim Operational Excellence Manager for a period of 12 months. This would result in higher operational efficiencies at sites leading to lower total cost of ownership.

Solution:

A ‘Voice of the Customer’ strategy was developed asking people all around the world affected by Supply Chain to give their thoughts With a limited resource, Operational Excellence had to be sure that their efforts were going into the right areas: Data analysis was carried out to indicate which suppliers the team would work with (geographically the team were spread around the globe) Lean Six-Sigma assessments carried out on several key suppliers Having chosen the suppliers, engagement was made through the Commodity Manager and issues investigated using the latest data following “Gemba with Purpose” at Supplier sites Subsequent steps involved direct contact with the supplier dealing with Operations Managers, Technicians and Operators to resolve issues using problem solving and performance management Results were monitored over time at the GSK site, and processes/standards amended where appropriat.

Results:

Supplier defect rates reduced from 5% to less than 0.2% Capacity at supplier increased by 40,000 units/wk with minimal increase in overheads Lean processes installed and work carried out, with GSK receiving site to improve process Commodity Managers coached on ‘Gemba with purpose’ n Strategy Developed to deliver Operational Excellence in procurement: Model latterly used GlaxoSmithKline Production System (GPS) Failure rates at GSK sites reduced from 5% to less than 0.12%


Client:

Apollo Fire Detectors

Location:

United Kingdom

Contact Title:

Synatus Partner:

Andy Dobson

Assignment Type:


Consulting

Role:


Discipline:

Business Transformation

 

Sector:

Manufacturing

Challenge:

Excessive stock holding in finished goods. Old, partly redundant stock

Solution:

Move to make to order structure using mass-customisation model. Redesign finished goods storage area to accommodate packing lines and introduce KanBans to buffer production against final demand.

Results:

Immediate return of £38k by reworking & selling slow/dead stock. Indicated one off savings of £3.6m by make to order vs. make to stock. Project worked out only to feasibility level in timeframe available but groundwork done, processes identified and cost to implement calculated (approx. £85k)


Client:

Niche

Location:

United Kingdom

Contact Title:

Synatus Partner:

Andy Dobson

Assignment Type:


Interim management

Role:


Discipline:

Business Turnaround

 

Sector:

Manufacturing

Challenge:

Parachuted into a struggling company following the dismissal of my predecessor. Issues: Most deliveries late, lumpy production (everything invoiced in the last week of the month).

Solution:

Found a fundamental mistake in the configuration of the company's MRP system. Fixed it in conjunction with the reseller. Reworked production flow and reorganised stores operation.

Results:

Better than 80% OT deliveries within 3 months for new orders. Reduced backlog of overdue orders by over 40% in same time period.


Client:

Niche Electronics manufacturer

Location:

United Kingdom

Contact Title:

Synatus Partner:

Andy Dobson

Assignment Type:


Interim management

Role:


Discipline:

Business Transformation

 

Sector:

Manufacturing

Challenge:

Returned to previous client to manage crisis brought about by my replacement! Poor OTD, rocketing stockholding costs, cash squeeze.

Solution:

Focussed on 'what we can deliver' and made sure we did. Reviewed full purchasing plan going forward, re-aligned production to maximise available materials and labour. Rework MRP system (again) to reflect shopfloor situation

Results:

Recovered business/cashflow and retained all clients. De-lumped the business, moving towards continuous despatch rather than everything in the last week/day. Recorded record monthly output(s) within 3 months and for subsequent period. Developed long-term relationships with customers and suppliers


Case Studies: 1 to 5 (of 5)
  1 | 2 | | |