In order to improve our
manufacturing process and the profitability of our business, the management of REYES CONSTRUCTIONSasked for an audit at the beginning of the year 2010 by an external consultant, A3 Management-I.
The necessity to have an outsider's
perspective in our Supply Chain and manufacturing process has been determinant to create a « break » and to progress quickly.
At the end of this audit,
the A3Management-I company as been selected and intervened on two of our sites for around twenty days in order to
implement Flow -Lean Manufacturing and to work concurrently on flows'
The goal was to maximise the
whole Supply Chain (upstream flow, production, downstream flow) by lowering stocks, the transit time for manufactured products in order to better manage our production but also to have a
better visibility of our flows.
The removing of « red » (costs non funded by the
customer) has been really efficient. The effectiveness raised up of more than 20%.
The « 5S » has been concurrently implemented.
The setting up of indicators for
the follow up of our action plans allowed us to bring new working conditions to the operators, they have a better view of the coming workload, their performance and especially, to the customer's
point of view.
A3 Management-Ibrought us tough and efficient working methodologies allowing us to highly reduce our cycles (an
average of 10 days), to have gain on our square meters of production
(around 30%) but also on our WCR.
A new method for controlling
process, allowing us to reach and to respect a service level of 98%, has been set on each of the manufacturing process.
All the actors of the
Supply Chain has been involved (from the management to the
operators but also our customers) in order to progress jointly. Relying on a
daily animation approach, the dynamic of implementation has been outstanding and quick.
The Lean has been integrated in an
ongoing process of improvement which will be implemented on every REYES CONSTRUCTION's sites.