A client I worked with in New Jersey in 2018 had a department that was operating at a 50% first pass yield rate, an 80% on time delivery and with continuous customer returns for defects that still made it out the door.
I developed a 10 month transformation plan for them and then executed it with them. I started out with determining what their part families were. It took close to two months to iron it out with them, but we came up with 3 part families that all of their parts fit within very nicely.
Then I led them in performing cell design analysis to determine the best layout for each of the part families. We were able to use the same existing footprint, laying it out very similarly, but in a very new way of operating it and with a lot less people. In fact, 2/3 less people.
I recommended that they stop hiring for their new business area that was in development and would be coming on line in about a year. The transformation plan took 10 months, so it was perfect timing. We freed up the resources just as they were needing to start training them.
Once the new cells were in place, they immediately hit and sustained 100% first pass yield, 100% on time delivery and stopped the customer returns.
I would love to bring this same type of breakthrough change to Connecticut manufacturers and help them get ahead of their headcount concerns, on time delivery concerns, quality concerns and supply chain concerns.
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