The issue
- An engineering, fabrication & assembly facility supplying deck machinery equipment to the marine industry, was severely underinvested in, with old facilities & equipment and remote from Group HQ
- Seen as a failing site with internal customers losing trust in its ability to deliver
- Disconnected planning and production functions causing late delivery and high costs
- No effective performance management system in place to drive improvements
- Very high inventories due to a lack of control of demand and production priorities
- Intention to transfer products in from Scandinavia and establish a low-cost supply centre of excellence
Solution
- Evaluation of the primary issues and development of a site transformation plan
- Focused on OTIF as the critical performance metric; established cross-functional planning with short interval control to manage demand and delivery to promise
- Improved data integrity, reset planning parameters and re-established ERP system use
- Re-organised operations to improve flow through the factory and to establish schedule adherence
- Implemented practical lean operational disciplines centred around PDCA
- Addressed excess inventory, control of stock, kitting and warehousing operations
- Established effective performance management across all functions
- Coached management to develop capability and establish sustainable improvement
![](https://www.curzonconsulting.com/wp-content/uploads/2023/02/Operational-Excellence-uai-258x145.jpeg)
The results
- Delivery performance improvement OTIF from 14% to 95% within six months
- 45% reduction of inventories within one year
- Jump in recovered factory revenues from effective demand management & increased delivery to commitments
- Engaged and productive workforce with a clear understanding of what was required of them
- Successful capital upgrade completed while continuing to supply
- Site was established as a Centre of Excellence for deck machinery and achieved Group award for excellence
- Asked to repeat a similar exercise at another site in the Far East
An award-winning team
![MCA 2022 LOGOS black WINNER](https://www.curzonconsulting.com/wp-content/uploads/2022/05/MCA-2022-LOGOS-black-WINNER-e1673534278663-300x300.png)
![MCA 2021 LOGOS black finalist](https://www.curzonconsulting.com/wp-content/uploads/2022/11/MCA-2021-LOGOS-black-finalist-300x292.png)
![MCA 2020 LOGO black FINALIST](https://www.curzonconsulting.com/wp-content/uploads/2022/11/MCA-2020-LOGO-black-FINALIST-300x292.png)
![MCA2019 LOGO_WINNER_black Curzon Consulting award winning team](https://www.curzonconsulting.com/wp-content/uploads/2019/07/MCA2019-LOGO_WINNER_black-300x300.png)
![Curzon consulting mca finalist 2019 Curzon consulting mca finalist 2019](https://www.curzonconsulting.com/wp-content/uploads/2019/05/wards-_0004_2018-300x300.png)
![wards-_0003_2017.png](https://www.curzonconsulting.com/wp-content/uploads/2019/05/wards-_0003_2017-300x300.png)
![wards-_0002_2016.png](https://www.curzonconsulting.com/wp-content/uploads/2019/05/wards-_0002_2016-300x300.png)
![wards-_0000_Layer-1.png](https://www.curzonconsulting.com/wp-content/uploads/2019/05/wards-_0000_Layer-1-300x300.png)
![MCA 2023 LOGOS black finalist 1](https://www.curzonconsulting.com/wp-content/uploads/2024/03/MCA-2023-LOGOS-black-finalist-1-300x292.png)
![](https://www.curzonconsulting.com/wp-content/uploads/2023/02/FT_UK_LMC2023_Logo_years_MC_19%E2%80%9323-1-uai-258x59.png)
![](https://www.curzonconsulting.com/wp-content/uploads/2023/01/CIPS-EIP-Awards-2022-Winners-Badge-1-e1678962375682-uai-258x147.png)