ELIMINATE THE COSTS OF EXCESS INVENTORY, MANUFACTURING LEAD-TIME, FLOOR SPACE, PRODUCTION AND PROCESSING
Generating more quality output with less resources and costs is the key to success in today’s competitive environment. Impactiva’s Process Optimization specialists will work with you to establish, implement and maintain a lean production system at each of your factories that removes waste while increasing quality, productivity, on-time delivery, flexibility and manufacturing capacity.
How it works
Your customized Manufacturing Excellence System will focus on the systematic elimination of waste and implementation of concepts of continuous flow and customer pull.
To achieve this goal, first we’ll hold a meeting to sync your strategic operating goals and strategic manufacturing goals, as well as nominate a Manufacturing Excellence Sponsor at each of your suppliers. A detailed, five-day Manufacturing Excellence Assessment will follow, rating the current operations of each supplier site in our 6 competencies: Leadership, Quality, Manufacturing, Delivery, Cost and R&D. Next we’ll gather data through interviews and floor inspections, assess opportunities for improvement, clean-organize all factory work stations, and implement managing for daily improvement.
Our Process Optimization specialist will then work with your site’s team members to align your strategic manufacturing goals with specific waste reduction project plans, which will be co-implemented by Impactiva-trained factory process engineer(s) and or key kaizen team members at each of you factories with our assistance and oversight. Subsequent monthly reports will be provided of project status, waste eliminated and savings achieved.
In addition, we’ll require that your supplier owners, top managers and senior supervisors attend a detailed learning and coaching program to fully understand the Manufacturing Excellence tools and goals, as well as their responsibilities. Operations leadership at each supplier site will attend a Manufacturing Excellence Learning Program, while top supplier leadership will attend a Change Leadership Coaching Program. This learning will ensure that the improvements made in your Manufacturing Excellence System are sustained, maximizing long-term efficiency and profitability.
Eliminate waste throughout your factories’ manufacturing processes. Produce significantly more with the same or less resources. Impactiva can help you turn around your manufacturing organization and enjoy the following benefits:
- Manufacturing capacity (increased throughput with the same resources)
- Labor productivity
- On-time delivery
- System flexibility (ability to react quickly to sudden changes in demand)
- Waste (material and finished product rejects, % of rework, etc.)
- Manufacturing lead-time
- Floor space
- Work-in-process inventory
- Working capital
TEAM AT YOUR SERVICE
The following Team will support the activities required to perform the Service:
- Process Optimization Specialists who have a proven track record of manufacturing excellence systems implementation delivering breakthrough results.
- Process Optimization Facilitator who will facilitate the Manufacturing Excellence Learning Program given to the operations leadership at each supplier site.
- Change Leadership Coach who will coach the supplier’s top leadership team so that they are aligned and focused on the role they need to play to fully support the Manufacturing Excellence System.
- Process Optimization BU Leader responsible for running the PO Business Unit.
- R&D Team responsible for gathering Manufacturing Excellence best practices and designing new improvement processes.
- Learning Team responsible for imparting lessons to the entire IMPACTIVA Process Optimization Team for all new processes and procedures developed by the R&D Team.
STANDARDS AND SPECIFICATIONS
We will meet with you to understand your company’s strategic goals for the next three to five years in order to then identify and agree with you, your Manufacturing Excellence strategic goals. This is the beginning and an extremely important part of your supply chain’s process optimization; it is the seed that will grow into your Manufacturing Excellence System.
IMPACTIVA AT THE FACTORY
We proceed to visit each of your factories to perform an in-depth five day assessment which defines their current level of excellence. Next, we develop a detailed value stream map to identify each factory’s “current state” and design the first “future state” with your team, based on your Manufacturing Excellence strategic goal priorities.
We then start each Factory’s transformation with a leadership development platform that comprises Learning on Manufacturing Excellence Transformation and Change Leadership Coaching. Learning on Manufacturing Excellence Transformation is designed to train the operating management at each factory on the basics of Lean manufacturing techniques. The Change Leadership Coaching aims at enhancing the long term vision and leadership skills of each factory’s top leaders in order to support the Manufacturing Excellence Transformation and sustainability of the system with continuous improvement practices far into the future.
Next step of transformation is laying a solid Lean foundation with basic coaching on lean concepts to factory kaizen team followed by implementing 5S (Sort, Set, Shine, Standardize and Sustain), conducting key kaizen events (identified from value stream map based on the priority stated within your Manufacturing Excellence strategic goals) and executing Managing Daily Improvement (MDI) systems. During this time, we will be coaching and mentoring the factory kaizen team on collecting the baseline data and on continuously capturing the KPI data to monitor the progress against the mutually agreed target. Finalized baseline data and agreed KPI Improvements will serve as the basis for the return on investment estimation for the selected key kaizen events which will be validated after the completion of each kaizen event.
After completion of each kaizen event, we build process execution discipline by training, coaching and mentoring the factory’s process engineers and/or key kaizen team members to maintain the work standards and standard work of each transformed process thus ensuring sustainability with continuous improvement.
OUR CONTRIBUTION TO CONTINUOUS IMPROVEMENT
As a final stage of the Manufacturing Excellence System, we build process execution discipline by training and supporting your factories’ process engineers and or key kaizen team members so that they are able to maintain executed processes and controls and create new ones, thus ensuring continuous improvement and long term sustainability.
WHY IS IMPACTIVA DIFFERENT?
A TRACK RECORD OF ELIMINATING WASTE
Our specialists are trained in identifying and eliminating activities that generate waste in labor, material, time and capital. Our proven Process Optimization programs allow you to do more with less by reinventing and re-engineering the speed, flexibility and resources required to develop, commercialize and produce your products.
UNMATCHED INDUSTRY EXPERIENCE AND EXPERTISE
As the world’s leading quality assurance company in the footwear, apparel, leather, leathergoods and outdoor gear industries, Impactiva brings unmatched expertise to each Process Optimization program. Our industry-focused experts will provide immediate value, helping you to quickly realize the financial benefits of more efficient, productive factory operations.
DEDICATION TO CONTINUOUS IMPROVEMENT
In addition to working with you to understand your goals and customize your Manufacturing Excellence and/or Product Launch Optimization plans, we will provide your key staff members with learning seminars and one-on-one coaching to ensure continuous, long-term improvement.