A ~$22B global business providing wire spools cut to size for multiple industries saw a spike in demand in a region. Demand exceeded capacity, creating inventory space issues and cost constraints.
Services Provided
Working collaboratively with the client, the team:
- Analyzed the supply chain network and identified the best solution to meet customer requirements, including growth
- Completed value stream mapping and block analysis to optimize the flow
- Evaluated equipment and labor needs through capacity planning including projected growth year over year
- Expanded facility with a new layout, additional equipment and labor resources
- Launched AI Hazard software program
Results
The company factory and supply base move were completed on time and on budget, with the client achieving 50% annual savings at the regional level.
- Closed several sites and repurposed processes from one site.
- Other metrics of the new operation included: 100% increase in efficiency; reduced flow from 5 to 50% depending on the operation; increased capacity by > 50%; increased safety vest compliance by 22% in the first 90 days.
