Business Issue New Purchasing manager in complex industry was not meeting expectations of the hiring manager even though the work history of the new purchasing manager had been excellent. Approach Used Flow consultants interviewed the hiring manager and the new manager. They were then able to identify the gaps in performance expectations and the specific action plans of the new manager. Flow … [Read more...]
All Case Studies
High-End Electronics Assembly Product Line Delays
Business Issue A high-end electronics assembly product line was experiencing long lead times, poor delivery performance, and high labor costs. The Fortune 50 manufacturer was experiencing chaos on a critical product set. Evidence of the chaos included the following;
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Low first-time yield
Long and unpredictable lead times
Poor delivery performance
High labor costs
Disappointed … [Read more...]
25 Percent Plant Capacity Increase Needed
Business Issue A 25% increase in plant capacity in less than one year was required by a global provider of oil and gas equipment in East Asia. To help them reach this goal, new leadership asked Flow Consulting to provide guidance and training. Approach Used
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Studied detailed data describing the plant's operation.
Worked with the leadership team to agree upon the correct standards and … [Read more...]
Welding Processes Constrains Facility
Business Issue The welding processes area of a large fabrication facility failed to keep up with production demands because of poor processes and materials flow. These constraints seriously affected the output of the facility and, more importantly, they were affecting final assembly at the customer level. Approach Used Flow assigned a production manager of the welding processes area and he … [Read more...]
Acquisition and Manufacturing Integration
Business Issue A Flow Consulting client recently acquired its number #1 competitor, leading to a potential increase of 40% revenue and over 1300 skus. Our client concluded that they did not have the skill set and internal resources to effectively manage the manufacturing move and business integration in the tight timing of four months. Approach Used Flow took a unique approach and provided two … [Read more...]
Incoherent Finished-Goods Dock Operations
Business Issue The client was running out of room to stage finished customer orders. Product would move to the shipping dock and ‘park’ wherever there was room. When it came time to load the delivery trucks, it was a treasure hunt across the whole dock to find all of the customer orders. With an additional 30% growth expected, the client knew that the current mode of operation would lead to … [Read more...]
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