Furniture & Wood – Production

Summary of the project


What was the challenge the client was facing?

  1. Delays in delivery to the customer.
  2. Inability to forecast capacity of the facility therefore leading to poor productivity and efficiency.
  3. Poor quality control resulting in defects during production.

What was the approach that was used?

  1. The team created values stream maps of the production process.
  2. Identified bottlenecks in the production and areas of improvement.
  3. Collected production data for all stock keeping units (SKUs).
  4. Based on the data, the team created a bespoke planning tool that connects online sales orders database to production. This tool can forecast production of the different SKUs over a given day.
  5. Created a system to record all quality incidents during production.
  6. Introduction of tools to minimise time spend during resolution and ensure quick escalation for major incidents

What were the outcomes that were delivered?

  1. Reduction in lead time estimated 50% reduction on process time.
  2. Improved production planning of the factory.
  3. Increased productivity and efficiency.
  4. Quality incidents are recorded and are reviewed monthly to prevent re-occurrence.

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