REDESIGN THE OPERATING MODEL and quickly improve service, quality and productivity performance
The organization was missing order commitments, losing inventory and running well below industry productivity benchmarks and the plant management team was in process of being replaced.
Project Focus
- Based on our assessment, a new workflow, new schedules, staffing models, organization model, work aids and procedures were developed
- In addition, many “quick hit” improvements were implemented to gain early performance lift and demonstrate positive changes to customers and staff alike.
Operating Benefits
- Reduced daily distribution pick up/drop offs 50%
- Back orders reduced 92%
- Plant productivity up 15% six months after implementation
- Carts going out full vs. 75% capacity
- Expediting of orders is eliminated (2 supervisors freed up)
- Supervisors re-deployed to supervise staff
- Program in place to separate rags/stain/rewash, reducing rewash costs, effectively addressing stains/rags
- Safety awareness program initiated
Key Changes
- Implemented integrated transportation and production schedule and work flow
- Implemented new workflow and procedures
- Implemented inventory management process
- Supervisors to manage workflow and staff performance
- Implemented Work Aids and Safety Protocols for front-line staff
- Implemented Recommended Work Environment Changes
- Implemented performance reporting to track service, quality and productivity
- Implemented over 90 “quick hit” improvements
