Introduction

Many of tier 3 suppliers face issues with the manufacturing efficiencies, causing troubles at client end.

Challenges

• Excessive downtime
• Inconsistent throughput
• Rising operational costs.

Project Milestones

1. Conducting a full diagnostic of supplier production floor using real-time data logging
2. Workflow mapping, and operator interviews.
3. Identifying Key inefficiencies in changeover times, machine maintenance scheduling, and inventory flow.

Our Solution

• Implemented Lean manufacturing principles
• Introduced a predictive maintenance system
• Optimized layout for smoother material flow
• Trained frontline staff in process standardization

Results

1. 28% increase in overall equipment effectiveness (OEE)
2. 22% reduction in unplanned downtime
3. 18% drop in per-unit production costs
4. Average product cycle time reduced by 1.5 hours