Manufacturing

Manufacturing consulting provides advice, direction, and coaching, while the company develops their own process improvement internal resources. This can be done in concert with tgg’s training services or independently on a project by project basis. tgg’s team is well seasoned in use of 3P, Box Scores, Daily Management, Kaizen, Leader Standard Work, RCFA, Runner-Repeater-Stranger analysis, and Single Minute Exchange of Dies. Many or all of these evaluation or improvement tools may help your plant reduce the gap.

 

A major element of this consulting is helping the team narrow their focus to a few key metrics for success, getting everyone in the plant to know how they contribute to those, and identifying and removing the barriers to achieving the goals.

 

Manufacturing:

• New Services/Products
  • Our manufacturing capabilities are inconsistent
  • Product development time is too long
  • Maintenance and operations don’t have the capabilities to support the new products
• Customer Order
  • No standard format for receipt of customer orders
  • Quoting = research project
  • Customers cannot view the status of their order
• Scheduling
  • The forecast is (really) wrong. 35% accuracy on a good day
  • Wrong inventory types and amounts on hand
  • Batch sizes are too large
• Design
  • We don’t have enough capacity – we don’t have the right capacity
  • We use 42 shades of white
  • BOM errors are not corrected which cause recurring problems
• Manufacturing
  • Travel distances in manufacturing are …. not short
  • We reward firefighters – the very behavior we are trying to prevent
  • The front office is consuming 80% of our promised lead time
• Maintenance
  • Rewarding reactive fire fighting
  • Data collection and use is very poor
  • Maintenance is under-manned, under-funded and under-trained
• Logistics
  • Expediting is the normal mode of business
  • Inventory $’s are too high – and at the same time service levels are too low
  • We have 100’s of suppliers – our network is simply too large
• Accounting
  • Needless reporting, reporting (did I mention reporting)
  • Duplicate invoices / payment errors are the norm
  • Standard pricing is incorrect and deeply flawed