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  • 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

Information

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

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  • 3 Production Sites

  • Mainly MTS Environment 

  • About €100 MM Turnover

Plastic Disposable Manufacturer 

Information
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  • MTO Environment

  • 2 Production Sites 

  • About €15MM Turnover

Metallic Carpentry Subcontractor

Information

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

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  • 2 Production Sites

  • Mainly MTS Environment 

  • About €125 MM Turnover

B2B & B2C Plastic Disposable Manufacturer 

Information