Multi-Site operations for the manufacturing of commercial and home products recently acquired a competitor. The company needed to standardize and streamline the operational best practices across all facilities. Immediate improvements were required to ensure customer satisfaction regarding quality and on-time delivery. The business had no existing improvement program, standardized process documentation, or KPI reporting. They also had limited exposure to Lean Manufacturing techniques through local college classes.
MetaExperts Chris implemented Lean Manufacturing across 7 US facilities in a structured process. He also created shop floor teams with daily KPI discussion and reporting. The development of support teams improved bottom-to-top communication and assured accountability of reaching goals. The principles of 4S, Ideas/Suggestions, and SoPs were engaged in all of the departments, including customer service, sales, and finance.
Executive management and cross-functional teams instituted Value Stream Mapping and conducted kaizen events in specific manufacturing and engineering areas. The business created bilingual training materials explicitly created for employee on-boarding. This training is now with their suppliers and customers.
By implementing an operational best practices plan across all facilities, MetaExpert Chris was able to help achieve 10 times ROI in the first 6 months of each facility.
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