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Merging two manufacturing sites

Company:

Electronic Components Manufacturer

Challenge:

Integrate two manufacturing sites, improve product quality and refocus the demand generation.

Approach:

  • Four-week Analysis & Design to align the management teams of both sites, design a process and structure to manage the sites in an integrated way, understand how to tackle the product quality issues, design the steps to refocus the demand generation and design the change programme.
  • en-month programme to implement the new management process, structure and team. Improved product quality by applying 6-Sigma tools. Installed TPM and improved both maintenance productivity and equipment availability. Moved most of the quality assurance to the operators and took out related quality resources. Changed sales from product push to market pull and aligned the innovation portfolio.
chips

Implemented an all-embracing organisational structure across the two sites.

A-grade production up from 20% to 91%.

Cost of poor quality reduced by 71%.

Client Requested Line Item delivery performance up from 55% to 84%.