Is your manufacturing floor feeling more like a pressure cooker than a powerhouse? Are you battling data chaos and frustrating delays that are eating into your profits? At Engage Forward, we specialize in transforming manufacturing operations using Lean principles, turning bottlenecks into breakthroughs. Today, we’re sharing a powerful example of how we helped a leading custom fabrication and assembly manufacturer revamp their office operations and completely transform their New Product Introduction (NPI) process.

The Challenge: Drowning in Data and Delivery Deadlines

Our client, a well-respected custom fabrication and assembly manufacturer, was facing serious operational hurdles. A poorly implemented ERP system, riddled with inaccurate data, was crippling their efficiency, making workflows take 2-6 times longer than necessary. Their NPI process was a major pain point, dragging on for a grueling 35 days (their target was a lean 5 days!). Daily influxes of new parts were overwhelming the production floor, leading to confusion, constant fire-fighting, and ultimately, late deliveries that strained customer relationships. Sound familiar?

Our Strategy: A Lean Transformation Roadmap

We knew this manufacturer needed a fundamental shift, not just a band-aid. Here’s how we tackled the challenge:

• Visualizing the Process: We deployed Lean tools like Value Stream Mapping (VSM), SIPOC, and mind mapping workshops to map out their processes, identify data gaps, and clarify roles. It was like creating a blueprint for efficiency!
• Defining Roles & Responsibilities: RACI charts helped us establish clear roles and eliminate confusion and duplicated efforts. No more wondering who was accountable for what!
• Creating a Feedback Loop: We implemented a quality tracker for information defects, creating a critical link between internal suppliers and customers. This allowed for rapid issue identification and resolution.
• Collaborative Improvement: Department and office-wide huddles became a central part of our strategy. These meetings fostered teamwork and drove continuous process improvement in a positive and respectful environment.

The Results: A Dramatic Turnaround in Manufacturing

The results were transformative:

• NPI Cycle Time: Plummeted from 35 days to an incredible 5 days – an 85% reduction, significantly accelerating innovation.
• Data Accuracy: Transformed from “Poor” to “Consistent,” drastically reducing errors, rework, and ensuring on-time deliveries.
• Hours Saved Annually: A staggering 3,714 hours of labor capacity was freed up for value-added work.
• Visual Management: Went from “Non-existent” to “Fully Adopted,” boosting transparency and communication across the board.
• Production Floor: Shifted from “Overwhelmed” to “Stabilized,” resulting in less fire-fighting, fewer delays, and smoother production flow.

How Lean Made the Difference:

Lean principles were the driving force behind this success:

• VSM and SIPOC provided clear insights into process handoffs and critical data gaps.
• RACI charts clarified roles, reduced confusion, and eliminated duplicated efforts.
• Workshops fostered team ownership and enabled the rapid implementation of improvements.

Conclusion:

By applying Lean principles to this custom fabrication and assembly manufacturer’s office operations and linking them to shop floor stability, we helped them achieve a remarkable transformation. Information accuracy skyrocketed, NPI lead times plummeted, innovation accelerated, and on-time delivery rates improved. We replaced chaos with clarity, delays with data accuracy, and rework with reliable workflows.

Is your manufacturing operation ready for this kind of transformation? Contact Engage Forward today to discover how we can help you achieve similar, game-changing results.