CASE STUDY SS-MD-DD-01 | Due Diligence

5X Efficiency Gains Through Targeted Operational Assessments

Eliminating Chaos: A Strategic Roadmap for Improved Efficiency

Medical Device | Due Diligence

Identified Efficiency Improvement Opportunity

↓ Variability

Reduced Cycle Time & Workflow Inconsistency

↑ Retention

Customer Retention & Market Competitiveness Gains

Challenge

Inefficient Workflow and Customer Service Variability

Unpredictable Customer Service: Cycle times varied significantly across product families. Inefficient CNC Scheduling: Changeover times were not optimized with run times.

Labor Allocation Issues: Labor was inconsistently utilized and prioritized, causing variable start-up times and output flow. Unknown Bottlenecks: Key constraints in the process were neither identified nor managed. Cycle of Chaos: The manufacturer lacked clarity on where to begin optimizing operations.

Solution

Data-Driven Operational Assessment

MRP System Utilization: Used existing data to identify large start and finish times at each work center. Dashboard Visualizations: Highlighted operations or machines contributing to extended TACT times. Labor Specialization: Recommended separating labor into set-up and running crews to reduce variability.

Optimal Staffing Suggestions: Proposed staffing strategies to improve efficiency and retain employees. Training in Quality: Addressed turnover issues and enhanced consistency through targeted training. Operational Segmentation: Analyzed performance by work center to pinpoint inefficiencies.

Results

Insight into Transformative Potential

Efficiency Gains Identified: Assessment uncovered opportunities for 5X improvement in efficiency. Customer Retention Opportunities: Highlighted potential to reduce lost customers and improve market competitiveness.

Foundational Plan for Change: Although execution was outside the scope, the assessment provided a roadmap for immediate and long-term improvements. Enhanced Market Positioning: Identified strategies to reduce operational chaos and become more competitive in the medical device industry.

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