Operational Turnaround
Our operational turnaround consulting services are applicable in private equity, aerospace, defense, automotive, medical device, and just about any type of manufacturing operation.
When Your Production Operations Need a Turnaround
Common Signs Your Operation Needs Intervention
If your manufacturing operations are unable to keep up with customer demand, our team can help. In the automotive parts production business, the inability to keep up with demand can cause costly interruptions in OEM production. Unplanned downtime, micro-stops, component unavailability, physical inventory not matching physical counts, and quality issues put the customer at risk and increase the pressure on operations.
The Cost of Underperforming Production
The cost of an operational crisis can be quite high. The hidden factory of over-inspection or rework quickly erodes margins. Paying operators to build defects, waiting for component parts to arrive at the line, or pausing for a machine to be fixed can be devastating to the bottom line; the cost of interrupting OEM vehicle production is astronomical.
Our Operational Turnaround Approach
1
Triage
In a crisis, we know it is critical to move fast. We perform an on-site assessment to get a rough estimate of the nature and scale of your challenges. Our goal is to determine what is required to make a rapid impact on protecting the customer, while also understanding that we might have to fine-tune our solution as we get into the details. Following the assessment, we provide a proposal for our recommended solution.
2
Execution
When executing operational turnarounds, we are only interested in permanent corrective action (PCA). This long-term solution is a data-driven corrective measure implemented after the root cause analysis to prevent recurrence, introducing an irreversible improvement.
3
Stabilize & Improve
Once we identify issues, we act quickly to protect your customers. Our rapid response team begins by implementing temporary measures, called containments, to stabilize deliveries and prevent shipping quality issues for customers. We ultimately peel back elegant, long-term solutions, remove containment, and implement sustainable performance improvements.
Throughout the process, we implement our managing daily improvement (MDI) tools (visual management, daily accountability meetings, and leader standard work) designed to identify, escalate, and resolve any abnormalities that could negatively affect production. We work beyond simple OEE summaries to move past things like availability and move deeper to improve reliability by drilling down in the data to assess things like mean time between failures (MTBF).
4
Training & Hand-off
Our goal is to restore your operations to meet your desired output level and hand it off once you feel equipped to sustain the improvements. Throughout the process, our functional experts pair up with your matching functional resources to train them on the changes we have made, how we interpret what we see on the shop floor, and how we react to that interpretation, so you can confidently manage your operations’ new processes.
What Sets Us Apart
At RPM Partners, we bring multi-functional knowledge with hands-on execution. Our experience spans OEE improvement, plant management, scheduling, planning, quality, supply chain, maintenance, warehouse design, PFEP creation, and logistics.
Ready to Stabilize Your Operations?
