The solution
- Brought together a cross-functional group of users to gather and agree on requirements, then set the project path
- Designed screens and workflow with frequent reviews against the original requirements, so there were no surprises at release
- Tested thoroughly, so the system worked as expected from day one
- Live loading for every work center, so the sales desk can give customers realistic ship dates when an order is accepted
- Scheduling of individual parts, not just whole orders, so multiple items run at once
- Color-coded parts with full instructions on touch screens at each machine
- Tolerance calculations done by the system instead of the operator
- Final inspection fed automatically to the CMM and laser measurement systems and compared with the customer order
- Completed parts move to shipping electronically, with support for partial shipments
- Rewrote the inventory system so it integrates with the shop floor system and the legacy order management system
The results
On-time delivery up from 30 to 40% to near 85%
Lead times down from 4 to 5 days to 2 to 3 days, a reduction of nearly 50%
Quality complaints down from an average of 18 to 20 a month to 2 or 3
Customers get ship dates up front and real-time order status
The company broke through its previous volume ceiling, growing from about $15M to about $25M in revenue, growth the client could not have handled on paper
Where this is going
We build the operational systems manufacturers run on, designed with the people who use them. If that is your situation, talk to us about scope.
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