Redesigned Production Processes to Reduce Total Cycle Time for Packaging Equipment Manufacturer

Challenge

A private equity-owned manufacturer of small- to large-scale packaging equipment had an inefficient and inaccurate production planning environment. The company required remediation actions to reduce order backlog and secure the correct raw materials and components to reduce total-cycle-time and deliver on time.

Approach

The SSA & Company team identified the core issues with bills of materials (BOMs) across core product groups, uncovered existing master data issues, identified and prioritized processes and system remediation. We also found improvement opportunities and created routings for flat BOMs, developed appropriate minimum/maximum levels with realistic lead times to ensure raw material availability, and redesigned production lines to create ideal flow and takt time at each work cell location.