MetaExpert Mark Reduced Consumer Inventory by 25%

Situation

A major Mattress Manufacturer was overwhelmed by their excess of inventory. Their inability to streamline had caused significant difficulties for the organization. Additionally, there were missing materials which greatly affected their production cost and ROI. In order to streamline inventory, and turn their production around, Mark, the MetaExpert, joined the organization.

Actions

Mark, the MetaExpert, worked full-time for 8 years and reduced the inventory by starting a process called Kanban and Consignment ordering methods. Mark was responsible for:

  • Troubleshooting the inventory control process
  • Ensuring the 'Vendor Lead' tasks were accurate
  • Streamlining the materials that were coming in by creating the right storage location
  • Accurately forecasting of order to consume
  • Initiating procedures to ensure the customer company only paid for items they used
  • Ensuring no orders were placed for production materials and non-essential materials
  • Figuring out the safest amount of safety stock to have at all times
  • Aligning with material staff to free up space for new materials
  • Forecasting and adjust orders accordingly based on the inventory at hand

Results

After deploying Kanban and Consignment inventory reduction methods, MetaExpert Mark and the major Mattress Manufacturer saw outstanding success with a 50% increase in production and inventory transition from 300 million to 800 thousand.

Besides, there was a fantastic increase in inventory terms from about 12 to 24 terms a year.

Mark got promoted from Receiving Supervisor to Purchasing Manager and stayed in the job for 8 years.

The customer was very happy with the results: increased return on investment, saving the amount of inventory, and increased production.

Return on Investment

  • 50% rise in production
  • Inventory reduced from 300 million to 800 thousand
  • Significant improvement in inventory terms from 12 to 24 annually

Project Details

Client Skills Required: OpEx understanding and deployment, Root cause analysis, SOP (Standard Operation Procedure), Stocktaking, procurement, Materials Manager.

Contract Length: 8 years – Promoted from Receiving Supervisor to Purchasing Manager

Support by MetaOPs

Manufacturing Insights Magazine named MetaExperts one of 2020’s Top 10 Lean Manufacturing Solutions Provider

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