Background

Company desired the automatization of the planning and production programming system

Invited us to help, discovering the physical process was complex

Our first recommendation was to simplify the process then follow on automatization

Project consisted in the simplification of processes, design and improvement of the information system

Structure

Inventory Policy

What needs to be in stock
How to identify stockable products
How to take into account seasonality

Planning Architecture

Visual floor control
Knowledge architecture utilizing Minimalist Theory
Order assignment algorithm between plants
Programming algorithm

Rapid Response

Assure a rapid response through a rapid change program
Remove process inventory cutting response time

Results

Reduction in delivery time inside the plant from 5 to 1.2 days for each roll

Service level improvement from 60% to 85% between 0 and 5 days

Inventory rotation from 12 to 42 rounds

Weekly programming time from 2 to 0.5 days

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