For any company that sells a product, the manufacturing space is the beating heart of the business. So when manufacturing operations are not running smoothly, it sends shock waves throughout the entire business. And that’s exactly what happened to this St. Petersburg-based awning company. We redesigned their manufacturing plant, streamlined production, implemented a prospect tracking system, and went fully paperless. The result? More sales, all-time high revenue, happier clients, and more!
At this Florida-based awning company, only 20% of the manufacturing space was being utilized. They also lacked a step-by-step process delineation for manufacturing operations. Without a systematic approach to production, the manufacturing process was bogged down by bottlenecks and inefficiencies. As a result, they struggled to get finished products out the door in a timely manner, leading to upset clients. Furthermore, they were unable to increase production in order to grow the business.
We completely reorganized their manufacturing space to streamline the production process. We also created custom development plans for every position in the business in order to improve talent management. Finally, we implemented a system for tracking orders and prospects so that the company could project revenue and plan for business growth.
Removed non-essential equipment from the production floor and re-organized manufacturing equipment for optimal efficiency.
- Utilized spaghetti diagrams to create an optimized layout for the manufacturing plant.
- Used swim lane diagrams to map out current state and future state of manufacturing process in order to maximize production efficiency.
- Created individualized employee development plans for every role in the business in order to improve talent management.
- Drafted clear job descriptions with tiered compensation plans and career paths to ensure skills-based compensation on par with industry standards.
- Implemented Heijunka boards to create a visual depiction of the work orders in each step of the production process. This stabilized incoming work, improved prospect management, and allowed the company to forecast revenue and plan for growth.
- Transitioned document management to fully paperless operation, which improved efficiency and accuracy of documentation.
- Systematically improved cross-functional and unilateral communications using SQDEC method (Safety, Quality, Delivery, Employee Empowerment, and Cost).
- Increased total sales by 20%
- Increased total revenue by 57% over a period of 8 months, achieving all-time high revenue
- Reduced time and costs associated with employee on-boarding and training
- Went 100% paperless
- Reduced production time and improved customer satisfaction