Global OEM – Material Availability
A global OEM operating in rail transport markets, active in the fields of passenger transportation, signalling, and locomotives.
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The Problem
- The business engaged the 4C Group to support production ramp-up at one of their manufacturing site. The client’s requirements were driven by three main challenges:
- Site had struggled repeatedly to ramp up production due to material availability issues.
- Lack of confidence in material availability forecast for effective decision making.
- The management team needed effective solutions to restore confidence and start the turnaround.
- Production ramp-up was essential to satisfy customer demands.
The Solution
- Combination of operating model changes and process excellence programme.
- Established supplier delivery review cadence to identify and resolve any issues proactively.
- Created a guiding hand ‘Redbook’ clarifying priority processes, KPIs and procedures for the operational execution team during the operating model transition.
- Data analytics and Control tower governance for material availability issue capture escalation, resolution and reporting.
- Material planning MRP parameters optimisation.
- Continuous improvement and change management programme.
The Impact
- Enabling increase in production by 50% over 6 months.
- Inventory reduction >50%.
- Successful Operating model transition and proving the concept for future projects.