Shortening the average material flow time by 10%
thanks to improvements in internal logistics in key sections.
What was achieved?
More predictable NPI implementations
sorting the carrying out of activities related to launching new products, with a clear division of roles and stages.
Stronger shopfloor management culture
introduction of regular operational meetings and clear rules for reporting and escalating challenges in production.
Clear action programme
preparation and implementation of an improvement programme for production and internal logistics, serving as a reference point for subsequent operational initiatives.
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Project challenges
The plant operates in an environment with high expectations regarding quality, timely deliveries and production flexibility. At the same time, optimisation projects and new product implementations for OEM customers are carried out. The company has decided to strengthen the management of production and internal logistics by engaging an Interim Launch Manager who will combine the perspective of introducing new products with the practice of process optimisation and developing a Shopfloor Management culture.
New product implementations
coordinating the introduction of new references for OEMs while maintaining the stability of current production.
Complex material flows
the need for a better organisation of the flow of components and finished products within the plant.
Development of shopfloor management culture
strengthening day-to-day management on the production floor and clear rules for escalating operational challenges.
Targets set
Effective introduction of new products
developing a structured approach to launching new references for OEM customers.
Improvement of material flows
analysis of current solutions and suggestions of practical improvements in internal logistics.
Strengthening of management (Shopfloor Management)
development of daily work rhythms, standards and communication rules on the production floor.
Increasing transparency for the management
preparing a clear programme of corrective and development measures in the area of production and internal logistics.
Solutions implemented
Analysis and improvement of material flows
review of internal flows, identification of bottlenecks and implementation of simple, practical changes to improve work flow.
Development of work instructions and standards
cooperating with the operational team to refine instructions for production and logistics and ensure their consistent application.
Strengthening of shopfloor management
implementation of regular shift-level meetings focused on the plan, current results and rapid response to deviations.
Action programme for production and internal logistics
defining key initiatives, timelines and responsibilities, which streamlined the way of working on improvements.
Client
The client was an international manufacturer of plastic components for the automotive industry that carries out injection moulding and assembly processes for several key OEM customers. The plant in Poland is expanding its portfolio with new projects by combining high-quality requirements with the need for effective serial production management.
Expert’s role and experience
Interim Launch Manager
The expert was responsible for supporting the introduction of new products into production and for initiating and coordinating improvements in material flows and production management. They worked closely with the operational team, change leaders and logistics representatives, combining OEM customer requirements with the daily practice of the plant.
Many years of experience in production management and NPI implementation in the automotive industry.
Practical experience in process optimisation, material flow and Shopfloor Management culture development projects in manufacturing plants.
Experience working in an international environment, including collaboration with OEM customers and operational teams in various locations.
