Background & the Client Challenge

The client designs, develops and manufactures high tech products for the Medtech and high-tech sectors. They work with clients to develop initial prototypes of products and then design these products for high-volume manufacturing.

3SIXTY was engaged to review the supply chain and operational plans for a product being developed within the client’s facility. Our objective was to ensure that all processes implemented were as lean and efficient as possible.

What We Did

Initially, we worked with the design team to look at the robustness of the design and in particular the design for manufacturability aspects. In our experience, often products are designed with absolute precision but can be difficult to manufacture robustly and repeatedly at scale.

By performing a robust Design for Manufacturing (DfM) review, we were able to ensure that the customer demand and production schedules were aligned and products manufactured right first time every time.

3SIXTY also implemented a robust Supply Chain and Operational Management process. This entailed detailed sales and operational plans (S&OP) – demand analysis, master planning techniques and financial planning covering a 12 to 18-month period.

Using Lean Manufacturing techniques, we ensured a “right first time” methodology would be implemented and work planning would become more visible. And, when issues did occur, these issues would be actioned immediately with the root cause identified and eliminated.

We also reviewed the full end-to-end supply chain and eliminated cost by implementing a “last mile” logistics solution. This involved developing a solution that shipped product direct from factory floor to the end consumer globally.

Results

  • Faster, more reliable solution resulting in financial savings for our client, our client’s client and the end consumer. Win, Win, Win

  • Significantly improved oversight of Operations (S&OP, Visual Management, KPI Management)

  • Development of process-based Risk Management

  • Development of robust quality measurement techniques

  • Standardised approach to the commercialisation phase of product development

Brian O’Brien

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