Tag: manufacturing

Assembly Magazine. October 19, 2022 by Harry Moser Geopolitical Forces Drive Record-Breaking Reshoring

Reshoring

Geopolitics Drive Nearshoring & Reshoring

“Geopolitical risk and the advantages of domestic manufacturing are motivating more and more companies to move production back to the U.S., driving job announcements to record-breaking highs.” Assembly Magazine’s October assessment reflects our own experience: reshoring’s proximity to end-use customers provides compelling relief from logistical issues, risks, and costs. Kormac...
Automotive Aftermarket Maximizing Throughput and Flow Kormac helped a leading manufacturer of truck caps, covers, and cargo systems to achieve: - 50% throughput improvement - 32% labor content reduction - Quality: right first time enhancement "Kormac found innovative and cost-effective solutions that improved Right First Time quality, throughput, and employee morale." - Client CEO

Automotive Aftermarket

Maximizing Throughput and Flow

A leading automotive aftermarket manufacturer was facing large impending order volumes and turned to Kormac for help in improving throughput, quality, and facility flow. Together, we developed a future vision for one-piece flow through their entire operation. Because new equipment proved cost prohibitive, Kormac and the client team sought to...
Cost Management Rebalancing the margin tug-of-war Does your organization struggle to achieve financial goals in an increasingly volatile marketplace? [iconography of two teams playing tug of war, with the target margin in the middle. Text above the image reads "Kormac Rebalancing"] Cost Pressures: Labor, Materials, Logistics, Real estate, Technolgy Market Pressures: Pricing, service delivery, quality, lead time, social responsibility Kormac's Surgival Strike Methodology™ delivers the agility you need to meet your financial objectivers.

Cost Management

Rebalancing the margin tug-of-war

As the labor and supply cost rollercoaster continues, we are working with several clients to identify new management levers. Among them: Increasing the frequency of cost reviews to ensure faster customer price adjustments and/or tying customer pricing to component market indices Executing Value Analysis and Value Engineering efforts to drive...
Lean Liberation Lean as Resource Liberator Sample Kormac Lean project outcomes - -50-60% cycle time reduction - -50% WIP inventory reduction - -85% cost of poor quality reduction - +30+% improvement in labor efficiency - +30+% EBITDA improvement - +20+% useable floorspace expansion - Overall improvements in safety performance and employee satisfaction

Lean Liberation

Lean as Resource Liberator

As manufacturers grapple with rising material and labor costs, we’re seeing renewed interest in Lean. Kormac has decades of experience in employing Lean/Six Sigma/Kaizen methodologies to boost quality, productivity, and speed while reducing cost, backlog, and facility floor space. We begin each Lean engagement by analyzing our client’s product line...
Global Manufacturing Supplier Visibility and Planning - Reduced airfreight costs by 43% ($47MM) with increased component visibility

Global Manufacturing: Supplier Visibility and Planning

Reduced airfreight costs by 43% ($47 MM) with increased component visibility

Continuing our discussion of current supply shortages and bottlenecks, Kormac excels at helping clients cultivate supply visibility and reliability amidst challenging conditions. For example, a global manufacturer of vehicle seats sought to maintain 100% OTIF (On-Time and In-Full order fulfillment rate) but suffered from inadequate visibility to component suppliers’ capacity...
Heavy Outdoor Equipment in front of a sunset. Photo by WORKSITE Ltd. on Unsplash

Heavy Equipment: Order Backlogs & Supplier Availability

Temporary supply shortages are making economic headlines as drivers of inflation and order backlogs. Kormac addressed the same uneven supply availability during the last recovery. One of our clients, a global Oil & Gas heavy equipment manufacturer, lost critical suppliers when the 2008 economic crisis drove many small machine shops...
Surgical Strike™ Transformed B2B warehouse to support rapid B2C delivery Throughput rose 593% from 3,500 packages per day to 24,270 per day with no additional labor Enhanced warehouse layout and processes for fast, cost-effective product delivery

Warehouse Throughput

Transformed B2B warehouse to support rapid B2C delivery

Pandemic retail disruptions have prompted many manufacturers to dramatically scale up direct-to-consumer sales. Kormac recently helped a consumer packaged goods manufacturer to transform its B2B logistics operations to support rapid, cost-effective B2C delivery. With our guidance, the client improved warehouse throughput from 3,500 packages per day to 24,270 per day...