MANUFACTURING PROJECTS
At the heart of LPMM, we have a belief that everything has a process and that once understood and measured, can be improved. We take great pride in delivering outcomes that exceed our client's expectations. Whether you're a multination or a family business, our passion and commitment to you is our cornerstone.
Process Improvement
The Problem
Our client, a global leader in online merchandising based in the USA engaged LPMM to review and increase there time to pick and dispatch processes.
Whilst our client was a successful business, they had a continuous improvement mindset and wanted to improve delivery times and productivity performance
The Solution
Using tried and tested lean principles, LPMM reviewed the complete end to end process from an order taken to delivery out and identified improvements. By using "Yamizumi,7 waste principles and Kaizen" LPMM identified three issues.
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Factory layout
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Poor product labelling
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Unnecessary walk time for the operators.
LPMM redesigned the picking areas across the site and introduced a Kanban system that ensured first in first out. We Visualised and monitored pick rates and installed new racking.
Results
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A 25% improvement in the end to end process time.
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Picking accuracy improved in all departments.
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Footprint improvement leading to an increase in products offered
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An ROI greater than 7:1 in the first year and 12:1 in the following years
Cost Control
The Problem
Our client, a 4th generation family printing business producing literature for the major car manufactures in the USA.
Our client, a major printing business had a full order book but had not made a profit for several years. In a last ditched effort to save the company, our client engaged LPMM to identify where it was not profitable and find a solution.
The Solution
LPMM reviewed the current processes and conducted a 'process mapping' exercise to identify bottlenecks, unnecessary overwork and efficient work methods. LPMM identified poor overtime management, a lack of production control leading to excess waste and a poor management culture.
LPMM introduced an overview planning methodology that reduced overtime and introduced "just in time" principles, a daily review was implemented across the management teams, and clear roles and responsibilities for each manager developed. A weekly senior management Visualisation was installed that allowed quick decision making and removed any unnecessary delays
Results
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The client made its first profit in 4 years.
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Overtime reduction of 80% recorded
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A complete change in the senior management structure completed.
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The client has since moved to bigger premises