Operations & Supply Chain Management

OPERATIONS / PRODUCTION RAMP-UP
– Heavy construction
machinery –

CHALLENGE

A heavy construction machinery manufacturer faced a strong orderbook, creating the need to improve operational performance and ramp-up production output

APPROACH

Stabilized production planning (FIFO), optimized line balancing, performance management controlling

QUANTIFIED RESULTS

35% increase of the monthly production rate

70% decrease in lost time due to missing parts

70% overall reduction in lost time within 6 months

OPERATIONS / OPPORTUNITY-TO-CASH
– High tech production
company –

CHALLENGE

Following a cross-border merger, a market leader in information engineering was faced with increased complexity of IT and operational processes

APPROACH

As-is process analyzed and major issues for long lead times identified, solution concepts for top 10 priorities defined, program management conducted

QUANTIFIED RESULTS

10% decrease in the end-to-end lead time

Cost decrease through footprint rationalization and consolidation

OPERATIONAL EXCELLENCE
– Mechanical design / plant engineering company –

CHALLENGE

A leader in plant engineering equipment wanted to drive operational excellence and increase supply chain transparency and implement management standards.

APPROACH

Design process diagram and activity-based workload-model from tendering to the project close-out defined, project steering standardized

QUANTIFIED RESULTS

Generation of transparency and management standards as basis for improvements​

€8-12m in savings through operational excellence estimated

MAKE OR BUY
– Increase competitiveness / aerospace OEM –

CHALLENGE

The production site of a tier 1 subcontractor for major commercial and military aerospace OEMs needs to increase profitability by focusing on manufacturing of elementary parts and assemblies with high added value

APPROACH

“Obvious” Make to Buy transfers identified, additional Make to Buy cases analyzed in more detail, priorities defined, implementation roadmap designed

QUANTIFIED RESULTS

>30% of the activity candidate to Make to Buy

>10M€ potential recurring savings

8M€ NRC to complete transfers

PROCUREMENT / LOCALIZATION & TENDER STRATEGY 
– Offshore infrastructure
project –

CHALLENGE

A market leader in oil and gas wanted to start building a new mega offshore infrastructure

APPROACH

Localization options identified and evaluated, procurement strategy & guidelines on major procurement tenders (contract value of ~ 1 $bn) defined

QUANTIFIED RESULTS

Infrastructure localization by enhancing procurement transparency and improving decision-making 

300 €m in savings on the delivery of main contracts

SUPPLY CHAIN END-TO-END REVISION
– Major ground handler –

CHALLENGE

A market leader in technical tubes for the aerospace market, was faced with a high level of supplier and customer delays, requiring a revision of the end-to-end supply chain.

APPROACH

MPS process defined and implemented (incl. short-term visual planning tool), S&OP process redesigned and implemented, workforce trained

QUANTIFIED RESULTS

43% increase of the on-time delivery rate

56% decrease in depth of delay (based on quantity and days delayed)

 SUPPLY CHAIN RESILIENCE / SUPPLY CRISIS 
– OEM for construction equipment –

CHALLENGE

A leading OEM for construction equipment was hit by the global supply chain crisis and faced supply chain shortcomings with consequential production issues.

APPROACH

Procurement lead times reviewed, manufacturing BOM tracker implemented for missing parts identification, enhanced expediting routines established for missing parts delivery

QUANTIFIED RESULTS

70% reduction of assembly down time due to stabilized supply chain

6% increase in production rates despite supply chain challenges