A global creative arts distributor needed help improving their on-time deliveries. Our client’s end-customer was about to replace them due to significant order backlogs. Our client had serious process, quality, and material availability challenges to solve.
Current State Analysis
The DISHER team walked through our customer’s current fulfillment process to understand their current flow of material and information. Value-stream mapping revealed waste in the form of excessive handling and traveling, rework, and workload imbalance.
Future State Design
DISHER guided the team using lean manufacturing principles in the development of a future state map. It eliminated complexity and addressed the root causes of the waste in rework, processing, transportation, inventory, motion, and waiting. Clarity and consensus were achieved.
The team developed an action plan, timeline, and a commitment for changes in picking, batching, processing, and inventory systems. DISHER supported the implementation with program management coaching, a new plant layout, and operational strategies.
Our customer saw a 90% efficiency gain with better quality, reduced overtime and inventory, and increased on-time deliveries. Their end-customer renewed the contract as a result of the notable improvements.