Design and implementation of build to sequence process.
(Duration 6 months)
Project lead for design and implementation of a sequence build programme for a new fully automated continuous moving flowline. Client required strong focus on integration between Supply Chain, Logistics, Quality and Operations to create robust material flow paths.
Factors considered
New Product range with highly configurable product
Significant investment on new production line showcasing lean principles
600 orders per week single shift
Transactional and operation process to be designed and integrated
Multiple material flow paths required (PFEP) in line with inventory turn target
Integration with 2 satellite facilities supplying core components
Integration with a sister company supplying core component located in mainland UK
Key steps applied
Process mapped the extended order to delivery value stream
Risk analysis for potential failures completed
Designed control metrics to manage sequence adherence
Used system-based planning tools to set achievable sequence (SAP ERP)
Designed multiple material flow paths and assigned component families to each flow path (Extensive PFEP utilising Pull, Kanban etc)
Executed plans on time and drove sequence build for start-up utilising daily weekly and monthly governance
Weekly updated communication plans shared with impacted team
Laser focus on change management
Summary of results
Project delivered on time and on cost
Stabilised supply chain processes
Extensive PFEP designed and implemented
Engaged cross functional team driving sustained Sequence build adherence 95%+
Full change management plan in place with integration between all teams and sites
Continuous improvement structure implemented with suite of KPI’s for measurement
Increased throughput by 40% within the same footprint
Blue print and capability for all future sequence build initiatives