Large supplier of aftermarket automotive solutions was consistently failing to meet customers cycle time requests. Customer expected 4-6 weeks total cycle time and the manufacturer took 60 days just to get the paperwork from customer order to the shop floor.
Flow Consulting facilitated a kaizen using a cross-functional team from Operations, Engineering, Customer Service, Production Control and Purchasing. The team mapped the entire 163-step process.
The supplier moved to a 12-step process that reduced the entire 60-day process to seven days. All customer orders were at the first manufacturing operation seven days after the receipt of the Purchase Order, and the solution was in effect within three weeks of the kaizen session.