Bridged leadership gap at high-growth manufacturer
Situation:
When a door systems manufacturer lost its VP of Operations, executives knew it could take weeks to find a qualified replacement. Moreover, the facility had recently moved and expanded, creating widespread disruption and a significant order backlog. The CEO turned to Kormac for interim leadership support.
Actions:
To help the plant meet growing customer demand for rail and road vehicle doors, our interim leader focused on:
- Reducing the backlog of work-in-process (WIP) doors
- Mapping and refining the Order-to-Invoice process to improve inventory accuracy and WIP visibility
- Addressing warehouse failures, including late shipments, invoice errors, inaccurate inventory, etc.
- Refining the capacity model and lead times
- Addressing general manufacturing shortcomings: quality, layout, ergonomics, cleanliness, speed, tool and consumables inventory, WIP storage, damage prevention, visual work standards, etc.
