Manufacturing
Productivity Improvement

A large Fortune 100 manufacturer of industrial ovens, refrigerators and freezers need to improve overall operating efficiency at its Ashville, North Carolina manufacturing facility. Daniel Penn Associates was called in for a four-month engagement to deliver immediate results.

We began our process by interviewing employees and assessing the plant situation first-hand, which allowed us to get a clear understanding of the problem areas. The functions that presented the best opportunities for improvement included bills of materials, production standards, routings, and process improvement issues.

Our expert consultants introduced a number of corrective measures including:

		Simplifying, correcting, and modularizing bills of materials;
		Improving controls over engineering routings and standards for product costing;
		Defining capacity planning; and
		Aligning sales forecasting, order entry, master scheduling and product costing in a single system.

The recommended program resulted in a number of improvements and cost savings, such as reducing the quantity of bills of materials by 90%, which in turn resulted in creating more accurate scheduling of product assemblies, plant capacities, and inventory control. What's more, our concepts and approach were documented to enable the company to rollout modularization to other divisions where applicable.

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