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
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
1st Tier Automotive Lean Logistics
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.