Case studyManufacturer of shower cabins •

Process improvement of preparing and processing a production order

Category: lean projects

General informations

The project was designed to improve administrative processes in a company manufacturing custom-made shower cabins.

What did the organization need?

The need to improve the process of document and information flow was related to the necessity to increase the effectiveness of order processing and improve the quality of activities involved in this process.

Main objectives

Improve quality of order processingImprove quality of order processing
Balance work in the design department
Standardization of operations in the administrative areas
Individual development of process managers
Improve interdepartmental communication

The course of the implementation

Design a current state map and plan a future state
Identify main problems in the process, determine a solution, deadlines and responsible people
Implement process indicators in the design area. Indicators are to be discussed during daily meetings
Conduct 5 sessions improving the management skills of the design department manager
Standardize the most repetitive processes

Results

Reduced processing time of one order by approx. 30%
Limited the process of double order verification by 40%
Developed tools to help eliminate redundant activities and unnecessary communication
Standardized over 30 routine operations
Developed skills matrix in order to systematize individual employee development paths
Linked incentive system with process indicators
Reduced overtime in the design department by over 90%
Developed new solutions, stimulated the team to report improvements (over 60 reported improvements during the course of the project)
Streamlined order flow thanks to setting priorities that included previously set lead time deadlines and market specifics
Focusing on priorities based on specific lead times
Monitoring of process deviations in short cycles (allows a quick response to quality and efficiency issues)

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Manufacturer of shower cabins