Realization



Engineer-to-order-manufacturing

Asahi Seisakusho

LETOURNEAU, INC

Ismeca Semiconductor

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Case Studies

Flow Based Planning and Execution Cuts Cycle Time, Improves Customer Satisfaction
Boeing's T45 flight training simulator development program applied flow-based planning and execution to cut cycle time, shave costs, and improve first-time quality.

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From Multitasking to Synchronized Product Engineering
A major supplier of large power generators increases its engineering output by more than 45%.

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Before & After

 BeforeAfter

Electrical Power Transmission, Engineer-to-Order
  • Throughput was 300 bays per year.
  • Throughput increased to 430 bays per year.

Power Transformers,
Engineer-to-Order
  • Engineering cycle time was 8 months.
  • On-time delivery was 85%.
  • Engineering cycle time reduced to 3 months.
  • On-time delivery improved to 95%.
  • 16% increase in manufacturing throughput (revenues).

Material Handling Solutions, Engineer-to-Order
  • Completed an average of 6.9 projects per year.
  • Completed 10 projects in first 8 months of 2009.
  • 31% increase in throughput-dollars.

Telecom Switches Design, Development & Upgrades
  • 300-400 active projects with 30+ deliveries a month.
  • Lead times were long.
  • On-time delivery was poor.
  • Throughput increased by 45% per person.
  • Lead times shortened by 10-25%.
  • On-time delivery improved to 90+%.

Telecommunications Network Design & Installation
  • On-time delivery was less than 75%.
  • Average cycle time was 70 days.
  • Increased on-time delivery to 98+%.
  • Average cycle time dropped to 30 days.

Manufacturing Plant Construction
  • 11 months industry standard project duration.
  • 7 months to project completion (55% additional revenue 4 months earlier).

Engineer-to-Order
  • 84 days overall cycle time.
  • 24 days production cycle time.
  • 15 machines in 8 months was highest throughput ever.
  • 64 days overall cycle time (25% reduction).
  • 10 days production cycle time (60% reduction).
  • 22 machines in 5 months (47% higher throughput).
  • 22% improvement in EBIT.

Oil & Gas Platform Design & Manufacturing
  • Design Engineering took 15 months.
  • Production Engineering took 9 months.
  • Fabrication and Assembly took 8 months.
  • Design Engineering takes 9 months.
  • Production Engineering takes 5 months.
  • Fabrication and Assembly takes 5 months with 22% improvement in labor productivity.

Engineered-to-Order Steam Generators
  • 20 casings per year.
  • 60% on-time delivery.
  • 27 casings per year (30% increase).
  • 90% on-time delivery.
  • 20-30% faster cycle time.

Automotive Assembly Systems, Engineer-to-Order
  • 70% of projects were late.
  • High overtime and outsourcing.
  • Lateness reduced by 50%.
  • 63% gains in productivity.
  • 15% more projects completed.

Custom Furniture Design and Manufacturing
  • Struggled to complete 200 projects per year.
  • Revenues were flat, business was just breaking even.
  • Completed 334 projects in the first 9 months.
  • Revenues increased by 88% and profits by 300%.

Equipment for Manufacturing Solar Panels, Engineer-to-Order
  • Revenues of €130 M. Profits of €13 M.
  • Cycle time was 17 weeks.
  • On-time delivery was 80%.
  • Revenues of €170 M. Profits of €22 M.
  • Cycle time reduced to 14 weeks.
  • On-time delivery improved to 90%.