Senior executives were concerned about quality and throughput at a market-leading manufacturing company. The company had made significant capital investments but had not seen the corresponding throughput results. The business required help to leverage and develop its current organizational resources to fulfill growing demand and take the business to the next level. Plagued by quality defect issues and facing a growing sales order backlog, management recognized that they needed to improve quality to drive enhanced throughput and increase profitability and market share. They invited us to work alongside their management team and newly-appointed Head of Quality to develop and implement a Quality Management Operating System and help them instill a new management and quality culture.
The Maine Pointe team found that the culture was one of ‘muscling through’ output. The company had no metrics in place and no quality measurements, disciplines or processes to help meet demand. Production was inconsistent and workforce turnover was high (around 40%). Management knew that they had a major problem but, with no quality systems in place, they didn't know how to get better.
Our approach to quality addressed every area of the business including, management, labor force, production, and operations. More specifically, our approach comprised:
The manufacturing processes, quality systems and management routines we helped to implement across the organization resulted in:
We didn't know the depth of the problem we faced until we had the right tools." V.P. Production