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Assessment and Shop floor Control

A Canadian supplier was experiencing numerous operational design and technical issues due to lack of responsiveness in tracking KPI’s, OEE and quality evidence. AMBE resources found there were several tool use and methodology differences that resulted in repeat issues with the final inspection and processes. AMBE resources implemented plant-controlled changes to the process, both temporary and permanent.

The Challenge

AMBE resources were brought in to support a Canadian supplier that was experiencing numerous operational design
and technical issues due to lack of responsiveness in tracking KPI’s, OEE and quality evidence. AMBE resources found
that communication between shifts was unclear in terms of how shift ran, quality and/or equipment issues, etc. There
were several tool use and methodology differences that ultimately resulted in repeat issues during the final inspection
and processes. The supplier’s major challenge was changing the teams’ approach, as problems and issues were treated
as events and not driven back to a systems solution, with no process to drive behavior.

The Solution

After initial week of assessment, AMBE resources identified several areas of opportunity both short and long term in
two phases:

1. PHASE 1: Change System – Focusing on the non-OEM areas and the warehouse procedurally:
Process Control, Change Management and KPI tracking/utilization.

2. PHASE 2: Implement Plant Controlled Changes to process- both temporary and permanent

The Result

OEM Audit Preparation

Before

Internal audit results with no improvement plan to prepare for audit

After

Reviewed suppliers internal audit results with supplier team Implemented improvement to audit score to prepare for audit
Product Production Processes

Before

Poor condition of fixtures, gates and facility Including non-functional and damaged gages. Repeat issues with final inspection

After

Implemented layout changes for improve efficiently and safety Recommended Bluetooth gaging application to reduce manual data entry wires
Quality Data & Metrics (Internal and External)

Before

No system or process in place to utilize and collect data. Lack of Evidence of OEE, quality And KPI’s

After

Recommended changes in trend visibility Initiated mapping of change management process(es)
5S Walks

Before

Work cells needed to be approved and layout enforced, maintenance, discipline needed to be culturized

After

Outlined value of documented daily 5S walk Identified safety issues Identified issues with labeling and paperwork
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