We Know How to Elevate Performance

• Part of a Global Multinational

• 3 Production Sites (Italy & Abroad)

• 6 Final Assembly Sites

• 12 Commercial Branches (Europe & USA)

• About €500 Millions Turnover

Large Industrial
Tier 1 OES

Pains

• Decreasing Demand

• Poor service level performance

• Long lead times

• Bimodal distribution of inventory (too much and too little)

Job Done

• 360° business and IT turnaround

• Implemented APICS best practices for Supply Chain

• Aligned SAP ERP to the new processes

• Industrial Control Model linking S&OP to Financial planning

Achievements

• 20% inventory reduction

• OTIF performance improved 300%

• Overall Economic result improved €30 MM

Pains

• Inventory Level too high

• Many slow mover products

• Long Set up times taking more than 17 hours

Job Done

• Implemented TOC Stock Buffer

• Constraints analysis and control

• S&OP Throughput Simulator

• TOC Throughput Economics

• Post go live coaching

Achievements

Within 6 months

• 25% inventory reduction

• Improved service level

• Results sustained and improved in the next years

• 3 Production Sites

• Mainly MTS Environment 

• About €100 MM Turnover

Plastic Disposable Manufacturer 

• MTO Environment

• 2 Production Sites 

• About €15MM Turnover

Metallic Carpentry Subcontractor

Pains

• Extremely long lead times

• Poor Customer Service Level on due dates

• Loss of sales opportunities due to lead times

Job Done

• Defined the TOC Time buffer

• Introduced WIP control by delaying the release of work and materials

• Constraint analysis and control

Achievements

• Improved OTIF close to  99%

• Lead times reduced 50%

• Minimized WIP

Pains

• Inventory Level too high

• Relevant use of subcontracting

• Many slow mover products

• Extremely long Set-up times

Job Done

• Implemented TOC Stock Buffer

• Constraints analysis and control

• Revised set-up process and capacity

• Applied Lean 5s and SMED to improve set-up times

• Post go live coaching

Achievements

• 26% inventory reduction in 4 months

• Additional improvements to service level up to 98,5%

• Results sustained and improved in the next 2 years

• 2 Production Sites

• Mainly MTS Environment 

• About €125 MM Turnover

B2B & B2C Plastic Disposable Manufacturer 

• MTO & MTS Environment

• About €40MM Turnover

• Part of a Multinational group

Diversified Manufacturer  Chemical & Mechanical Products

Pains

• Too many late deliveries in the MTO segment

• MTO Lead times extremely long

• High inventory levels in the MTS segment

Job Done

• Stock buffer in the MTS

• TOC Time buffer for MTO

• Constraint analysis and control

• Throughput accounting controlling and decision making

Achievements

• OTIF improved close to  99%

• Lead times reduced 50%

• Minimized WIP