Case Study :Business Transformation
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Restructuring the Business Operations
A manufacturing was suffering from slow growth and diminished market share. To remain competitive, it needed to improve its manufacturing facilities to reduce cost and increase capacity. It also need to invest in innovation to remain competitive. Praxis Value Incorporated Lean Six Sigma principles to improve the company’s plant performance, which yielded 15 percent cost savings and increased flexibility.
2 min Read | Metal Manufacturing
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Challenge
Plant was losing market share to strong competitors and suffering from slowing growth in primary channels. To remain competitive, the client has to improve manufacturing facilities to reduce cost and increase capacity, and invest in innovations needed for growth and competitiveness.
The primary questions that need to be addressed were:
- Can we increase the capacity existing business units? How much, and where?
- Can cost per ton be reduced on the existing manufacturing lines?
- Can enough working capital be freed up from operations?
- What all innovations need to done for secured future?
Solution
Lean Six Sigma
Praxis Value incorporated Six Sigma DMAIC methodology and Lean principles into our five-step approach to improve plant performance. Also, designed & implemented a ‘Change Network’ to create sustainable change. This model is responsible for owning, assessing, and monitoring change before, during, and after the program is rolled out.
Prioritise Key Initiatives
Praxis Value identified 30 initiatives and prioritized them according to improvements to plant capacity and overall equipment effectiveness. Of these, we recommended twelve as the most critical initiatives. These critical initiatives were directly handhold by Praxis Value team in all the phases of the project Lean & DMAIC methodology.
Lean Six Sigma Process Simulation
In parallel to the implementation of the Lean Six Sigma business process simulation was performed to evaluate the effectiveness of the processes and refine them, and develop entirely new methods, it enabled the plant process analysis that gave the information and insight to implement with confidence.
Outcome
With Praxis Value support, plant implemented the recommended initiatives, generating 15% cost savings, Improved capacity by 28%, Increased equipment effectiveness by 22% and also helped in increasing flexibility. The company also worked with Praxis Value to put knowledge transfer programs in place so that the improvements would spread to additional plants in the system. Once the business transformation program is complete clients expects to save millions per year in terms manufacturing efficiency and headcount reduction.
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Through simplified, standardized, and automated processes, we established a scalable platform of ‘growth without growing’ that will support the organization’s go-to-market strategy.
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