Custom Machine Manufacturer

About

A Custom Machine Manufacturer was facing flat sales, back log of projects, and quality issues.

Unsure of what was driving these issues, they engaged ECS for a “Fresh Eyes” diagnostic review of their operations.

Objectives

Perform Fresh Eyes Diagnostic

Focus on culture of the company and identify critical areas of concern

Value stream map the customer order process from request to delivery of finished materials

Identify areas of operational improvement

Phase 1

Define

ECS & Client team - alignment of perceived areas of concern, approach and goals of program.
Discuss risks and potential constraints of success. Establish clear lines of communication and expectations.

Phase 2

Measure & Analyze

ECS conducted a Fresh Eyes Diagnostic as well as, one on one meetings to dive deeper into company culture and process through a start/stop/continue format.

Key Stakeholder Value Stream Mapping session – focused on customer sales from point of request
for an estimate to delivery of final goods.

Phase 3

Develop Strategy

Developed a “road map” strategy, providing sequencing of opportunities, focusing on four key areas
contributing to the lack of performance.

  • Communication
  • Team Morale
  • Skill sets
  • Processes
Phase 4

Execution

ECS worked collaboratively with the client’s leadership team to establish departmental action plans,
clearly aligning ownership and accountability throughout the organization. From there, the ECS team
guided the client team through the execution and implementation of the plans.

Outcomes

193/267 OF THE COMMENTS FELL INTO 4 MAIN ISSUES

  • 33% OF COMMUNICATION
  • COMMENTS WERE
  • SPECIFIC TO OWNER/ GM.
  • SET UP/BREAKDOWN,
  • INSPECTIONS,
  • AND ESTIMATING.

Communication

  • HR focus- organizational structure, roles, and responsibilities

  • Rules of engagement among leadership

  • Team meetings- expectations settings

Morale

  • Red tag process-
    shop clean up

  • Employee sessions
    with leadership

  • Inclusive in needs assessments and
    problem solving

Process

  • Sales and estimating

  • Full process
    reengineering or preproduction and post

  • Manual vs Computer