Does your factory have the flexibility, speed and response to keep pace with changing market dynamics?
At what cost are you meeting your customer requirements?
Are your lean projects driving results to the bottom line?
Is your factory truly Demand Driven with full Pull production capabilities?
Traditional scheduling techniques are embedded as the planners’ method of choice in many companies. The master schedule, overly reliant on inaccurate forecasts, mirrors the unresponsive nature of the factory floor. Outdated MRP principles and factory focused lean initiatives contribute little to the flexibility and speed and response needed to keep pace with variable and sometimes volatile customer demand. As a result, companies, similar to your organization, are only able to maintain customer service levels through holding inventory buffers throughout production and in Finished Goods.
In the factory actual work content is probably measured in seconds, minutes or hours. Certainly not the multiple days or weeks that products seem to take through manufacturing. With manufacturing delays, actual customer demand is further distanced from the daily plant performance and execution.
This is all too typical in the factories we visit and work within, there is just a huge gap between customer expectations and production capability.