Client

1st Tier Automotive

Scope

Eliminate chronic material shortages for a key sequencing plant with turnover in excess of £1bn

Diagnostic

  • Materials assessment
  • Logistics diagnostic

Actions

  • Introduce lean logistics provider to optimise routes across Europe
  • Establish supermarket and line-side delivery based on pull, Level scheduling of product, and the de-activation of ERP launches
  • Plan per part mapping to improve bill of material accuracy
  • Elimination of high bay storage

Results

  • £12m one-off inventory saving
  • Line stoppages due to material supply reduced to zero
  • Line delivery to OTIF improved by 46%
  • 100% of material controlled by pull systems within an 8 week production horizon

Logistics are often an afterthought for many businesses, whereas the Lean methodology for success has shown that putting Logistics first in the value system can often transform a company.

Putting Lean Logistical Practices in place can help to improve line stops, inventory turns, materials management, and work-in-progress.

Our lean consultants have repeatedly helped companies move from just-in-case inventory management to dynamic pull systems with levelled production and Kanban systems suited to their environment.

Trialled and perfected transformation method

GENEO has developed a unique deployment model to accelerate your Lean transformation. Contact us to understand how GENEO can help boost your Lean transformation.

Continual success stories

GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.

Leadership training

We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
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