MS Companies Clears 11,000 Backlogged Parts in 4 Weeks for a Tier 1 Supplier
MS Companies
Technology-driven workforce solutions provider to manufacturers across the US, Canada, and Mexico.
About The Customer
Our client is a Tier 1 supplier and a leading manufacturer of diverse products, primarily serving the automotive, industrial, and consumer markets. The supplier produces high-quality components such as automotive interiors & exteriors, technical foam products, and polyurethane, rubber, and plastic components.
Challenge
In May 2024, a major OEM contracted MS Companies to support one of their Tier 1 Automotive suppliers in Mexico. This supplier faced significant manufacturing challenges, including a substantial backlog of parts and a lack of clear capacity understanding. The difficulties included inconsistent discipline in measuring hourly output, production losses during shift changes, and limited insight into production capacity, which complicated efforts to meet demand.
Solution
To address the challenges faced, MS Companies executed a multi-faceted strategy that significantly enhanced operational efficiency and production capacity:
Capacity Analysis: Conducted a detailed analysis of capacity per part number to understand production limits.
Bottleneck Identification: Identified and analyzed bottlenecks in the production process.
领英推荐
Two-Phase Action Plan: Created a two-phase action plan targeting short-term (5 days) and medium-term (15 days) solutions, with daily follow-up meetings to monitor progress.
Daily Progress Monitoring: Established daily follow-up meetings to track the implementation and effectiveness of action plans.
Value Stream Mapping (VSM): Analyzed material and information flow to streamline operations and eliminate waste.
Overall Equipment Effectiveness (OEE): Measured and improved equipment efficiency to maximize production capabilities.
Results
The structured approach and dedicated efforts led to significant improvements for the supplier. The backlog of 11,000 parts was completely cleared within 4 weeks. Material flow through the production process was significantly enhanced, and a detailed capacity analysis provided a clear understanding of production limits. Shop floor discipline was improved with basic controls such as productivity measurement and downtime tracking.
If you are interested in starting a project with MS Companies, please contact us at [email protected].