The entire operational system of a company operating in the automotive supplier, spare parts, module, and component production sectors—generating the majority of its revenue from exports—was reviewed and redesigned within approximately 2 months.
The overall value chain of the company, which has 2 main production lines, over 10 product categories, and more than 1,500 product types, was analyzed, and the manufacturing operations were evaluated using a manufacturing cell structure. In addition, the contributions of all support functions to production were assessed.
As a result of the efforts, the following were achieved:
- Developing Six Sigma / Continuous Improvement approaches for process flow improvements
- Mapping inputs, processes, and outputs for all production processes and 9 main departments, including 5 directly related to the production line operations
- Defining and measuring level-1 and level-2 metrics for all departments
- Creating a metric structure in a pyramid format to ensure that the operations support the company’s overall strategic and financial metrics and presenting it to all departments
- Enabling all operational units to know how to track their prioritized and detailed metrics
- Listing the technical improvements needed in the Enterprise Resource Planning (ERP) system for the necessary follow-ups
The upper management’s action plans for implementing the designed operational system within 6 months and 6-12 months were outlined. It was observed that the company also initiated a new ERP software implementation process in parallel with this system design. During the ongoing phases of the project, an additional 3 months of support was provided to the company to help implement the follow-ups and methodologies. Significant improvements were achieved in the company’s overall efficiency, equipment effectiveness, and production volume parameters.
Additionally, to expand the company’s performance improvement program, unique work uniforms with a distinctive slogan and logo were designed to strengthen internal communication and were distributed across all production cells.
