Process Improvement

Cross-Functional Disconnect and Order-to-Delivery
Situation MetaExpert Kellen was brought on board to lead a study that focused on lean policy deployment and order-to-delivery (OTD) improvement. According to MetaExpert Kellen, current state analysis determined that there was:  no visual management no leader standard work no cross-functional communication or collaboration no daily metrics tracked or reviewed no daily structured problem solving no cross-functional training or knowledge understanding across departments or production floor processing capabilities In addition, product sales had increased by 35% with no capacity planning or production availability preparation.  Actions MetaExpert Kellen leveraged his expertise in process improvement strategies to get the company back on track. He was able to: achieve lean policy deployment implementation,  complete and develop cross-functional training  Develop and utilize plant capacity model to align sales team with operations available capacity and capabilities develop and improve router instructions for the scheduler to properly utilize plant equipment capabilities and capacity Results/ROI MetaExpert Kellen’s…
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Effective communication is needed in all areas of life. Paul Meyer hits the nail on the head when he says: Communication – the human connection – is the key to personal and career success. While basic communication skills are inherent, becoming a great communicator takes practice. You can start improving your own skills today by learning these four tricks of effective communicators.  Effective communication begins with listening. Too many times, people are either thinking about their responses or about something else entirely, and they fail to completely listen to the other person. By doing this, you lose focus on the conversation and may find out, in embarrassment, that your response is completely off base. When you are not listening, you are creating a one-sided conversation that shows others that you really do not care about what they have to say. Showing a genuine interest in learning what others think and…
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Vincent Steers Vehicle Manufacturer in Right Direction with VPS
Situation A luxury vehicle manufacturer in China was seeking to apply the value-added production system (VPS) rule and method as the company’s sister plant in Europe. The target group of trainees was area managers and section leaders who are responsible for more than 600 people across multiple plant locations. The vehicle manufacturer’s goal was to address the process issues at the lowest level in the organization with the end result being the shop floor employees taking the initiative to improve process performance. Actions MetaExpert Vincent conducted more than 800 hours of in-person, classroom training on the VPS subject as well as on-site improvement coaching at the vehicle manufacturer’s facilities across China. Vincent meticulously trained and coached the area managers and section leaders of each plant. He mentored the managers and section leaders on the following skills and principles: Transfer the eye of wasteLayout improvement Use of support chain Standard of workSpecific vehicle…
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Process mapping forms the basis of how business gets done on a daily basis as well as how the consumer-facing experience reflects those processes. Indeed, for a process to be a positive experience, it should be well-defined from beginning to end; and it all starts with mapping, refining, and codification.  Define the Sequence. For a task to be done efficiently and consistently, each step needs to be defined in a sequence of events that results in a defined goal. Mapping is the organization of how to arrive at a specific goal. Be it just starting your day on the “right foot,” or getting to the moon, it takes a schema of events that creates a chain of planned actions that reach a goal. There can be any number of schemas to reach the same goal. Mapping is the act of choosing the best path to a goal. The Critical Path.…
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Changing the World One Process Improvement at a Time
Ron Emory is a Continuous Improvement Consultant, Author, and Entrepreneur, and we’re proud to have him on our team of MetaExperts. Ron was recently highlighted on Supply Chain Game Changer as a leader in the supply chain process improvement industry. One of the things that make Ron unique is his background. Ron has traveled the world doing what he loves. “I have flown over four million miles, been on every continent but Antarctica, stayed in a hotel nearly 3500 nights. So, I guess that qualifies me as a “road warrior” but it really has been a fun ride and fun life.” He went from permanent roles as VP of Supply Chain to VP of Operations to consulting to owning and operating his own business. Although he is a leading expert in process improvement, he doesn’t hold a degree in Industrial Engineering like many of his contemporaries. Ron holds a liberal…
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Process Improvement - Construction Heavy Duty Equipment Company
Situation MetaExpert Brunno employed his process improvement acumen to aid a construction heavy duty equipment company with inefficiencies in their paint shop production. The paint shop was experiencing a period of growth and needed to adjust operations to accommodate the increase in daily production with limited time and the existing shop-floor team. High level of diversity for the parts painted, using two colors. Actions Brunno carefully observed the paint shop process and initiated the following actions to increase productivity: Reorganized layout of paint equipment.Studied the best way to paint the parts in the paint booth, looking to match the color, the size, and the time spent to paint any one part. Mapped the flux of parts throughout the shift and streamlined their sequence. Brokedown paint sequence and elaborated on the process sheet.Trained the paint shop operators regarding the new process. Increased shift by 1 hour to reach the production goals without hiring additional…
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Evaluating Indirect and Direct Factors for I.40 ROI
“Think of the tangential benefits from the Space Program” In July, the World celebrates the fantastic Journey that Apollo 11 performed in 1969 when the first men were sent to orbit the Moon. Just think of what has happened as a result of the single-minded goal of putting a man on the Moon. At that time, the total computing power needed for that effort was less than the computing power of a smartphone. The main computers that powered the Apollo 11 mission were the size of four refrigerators!  Most likely, the majority of us don’t remember the protests at the spending ($40 billion for the entire 12 years of the NASA Man-on-the-Moon project), but looking back, just look at the unforeseen benefits of the digital age. Technology has shown itself to have the capacity of producing exponential ROI …in hindsight. The Investment of Industry 4.0 When considering the important investment…
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excavators construction quality control
Situation A building and construction company brought MetaExpert Alan onboard to help sort out operational and logistical inefficiencies regarding the construction of metal structures. The company was facing a 100% sorting and rework rate of their products after manufacturing. In addition, as a result of the focus on inspection after product completion, rather than during production, deliveries were delayed. Actions To remedy the construction company’s quality control issues and delivery delays, Alan took the following measures: Reviewed with the team all applicable specifications to ensure all employees understood the requirementsDeployed the requirements to Key Process Control Parameters, not just final quality controlDeveloped the processes to be robust according to the requirementsImplemented control plansAudited process parameters and key characteristics, not just final goods Results Through his initial assessment, Alan was able to determine that a lack of communication and too many “experts in the room” was a major contributor to the…
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Automotive Giant Back on Top with MetaExpert Help
Situation A multi-billion-dollar tier 1 company became involved with a customer regarding a safety issue in which the customer was accusing the supplier to be at fault, thus revoking all 3 supplier manufacturing site locations for Q1.  This put the tier one supplier on new business hold and at risk of losing additional business they had plus additional quoting of new business opportunities. The company reached out to MetaExpert Jack for his APQP Process understanding, Advanced Critical Chain / Critical Path Methods knowledge, 5S and Standard Work expertise.  Actions Jack guided the organization to meet the challenge and improved productivity and facilitation of quality training and awareness. A collaborative cross-functional team of production, purchasing, engineering, and management was formed and led through a decisive 1-year plan, which involved the customer. This allowed for all key milestones to be met such that Q1 customer endorsement letters and Q1 site certifications were…
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Major Retailer
Situation MetaExpert Daniel served as Project Manager to a well-known clothing manufacturer and retailer with over 1,1000 stores located on 3 continents. Daniel’s proven expertise was key to substantial cost savings and process improvements. Actions A key part of Daniel’s role in overhauling this Major Retailer’s logistics process was to provide the initial kick off strategy guidance to Executive Management. Thanks to his track record of operational excellence, Daniel’s first step was to conduct due diligence with internal and external resources to capture the “AS IS” state of logistics operations. He then created a Work Breakdown Structure for the Project Plan to realize the “TO BE” state.  Once Daniel had determined the end-goal for this Major Retailer’s logistics, he: Developed, monitored, and controlled the Project Plan Conducted a weekly status update meeting with the Executive Management team Created and administered RFI. Created RFP, disseminated, crafted scorecard, and scored RFP responses…
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