Dumontis

Poor service performance, limited flexibility with high inventories, creating a risk for losing market share. Traditional push-based production control (using APS and MRP).

Transform 1,500 FTE site into a JIT operation improving service, flexibility and working capital and increase the autonomy on the shop floor.

Current state analysis, development of a shared roadmap and future state, execution of the roadmap implementing leveling and multiple pull flow loops from customer to supplier (shipping, finishing, hot and cold rolling, casting) in several phases, involving intense cross-functional gemba work.

A massively transformed site leading to a reduction of 75% in miss-deliveries and 45% in DOH, with more autonomy of operators and team leaders in managing their material flow.