Brandix i3 Business Improvement

Transcription

1 Brandix i3 Business Business Transformation & Specialists About Brandix i3 We are Business and Enterprise Application Specialists offering Infor M3 Consulting, Business Consulting and Enterprise Software Development Services. Our team comprises of more than 200 extensively qualified, multi-skilled, experienced professionals including Lean Six Sigma, PMP and Infor certified specialists. Our project experience spans across the Fashion, Healthcare, Food & Beverage and Manufacturing industries with engagements in the United States, Mexico, Russia, Pakistan, India, Sri Lanka, Bangladesh, Singapore, Malaysia and Australia. What We Offer Speed Cost Lead Time Reduction Supply Chain Yield & Material Utilization Waste Elimination & Overhead Reduction Capacity Optimization Production Planning Optimization Production Efficiency Idle Time/Changeover Reduction We are part of the US$ 700M Brandix Group, a regional apparel conglomerate and strategic supplier to Victoria s Secret, La Senza, Gap, M&S and H&M. Our Team Quality First Time Right Yield Rework and Scrap Reduction 130+ Projects Lean Six Sigma Black Belts, PMP Project Managers and TPM Certified Practitioners Wide Cross-industrial & Functional Expertise in Strategy, Planning, Budgeting, Accounting, Production, Merchandising, Material Planning & Engineering Across Operations Measurement & Performance Management Executive Dashboards and Cockpit Charts Process Mapping, Re-engineering and Auditing Six Sigma To Maximize Process Output Quality Through Defect Reduction TCT To Reduce the Time to Complete One Cycle of an Operation, Function, Job or Task Lean To Preserve More Value with Less Effort TPM To Improve Productivity of Plant & Equipment

2 Selected Business Success Stories Yield in Manufacturing Large apparel manufacturer catering to the world s top sports brands Vertically integrated operations US$ 110M Turnover Significant margin erosion identified at post-costing analysis Increasing number of defects detected at final audit High fallout of non-shippable units Identification and analysis of defects and process barriers Implementation of measurement system and defect detection points Statistical analysis to identify root causes and eradication of the causes Identification and eradication of process barriers Process re-engineering and standardized work practices Skill gap identification & training of associates Material Wastage Reduction Functional Context Functional Context Large scale manufacturer handling material worth US$ 60M annually, catering to world renowned fashion brands Specializing in woven casualwear Increasing cost of direct material resulting in lesser margins Material wastage exceeding 1.5% in the manufacturing process impacting order management and stock control Identification of the reasons for high wastage through process analysis Formulation of innovative material allocation tool for specific demands of different orders Mistake proofing the process through an Excel tool and subsequently with a software solution linked to process system 95% Yield Ratio from a baseline of 91% Development and establishment of Standard Operating Procedures (SOP) ERP modifications to track performance and Automated Defect Analysis Training Plan for Skill Development of operators Annualized savings of US$ 450,000 achieved 1% improvement in Material Utilization Removed the extra burden of reordering & issuing of small raw material quantities & reprocessing Adjustment of the Order Matrix to reduce the wastage US$ 370,000 savings in the first 6 months 4% by the 6th Month Project Payback in 4 Months US$ 450,000 savings in the first year 1% by the 2nd Month Project Payback in 6 Months

3 Selected Business Success Stories Throughput & Efficiency Functional Context Subsidiary of the single largest manufacturing exporter in Sri Lanka Specializing in intimate wear with turnover of US$ 36M Value stream mapping to identify bottlenecks Standard-work studies to assess capabilities of different units in the production process Demand-based Perfect Supply from central location to multiple end locations Functional Context Centralized processing and distribution facility distributing inputs to multiple locations with turnover of US$ 20M Identification and analysis of the process of distribution and production including production planning Decreasing margins due to the very high cost of production High Lost-Time Input delays at end function Implemention of operational model to improve resource utilization Establishment of a structured management approach and training of associates to ensure sustainability Identification of Lost-Time categories and elimination High logistics costs and increasing cost per piece High re-ordering of raw material High rework due to misplaced articles Challenges in meeting customer product mixes Implementation of pull system through Kanban system with end to end visibility of the requirement Value stream mapping, cutting capacity configuration, 6S and visual management to improve efficiency Implementation of production planning tool to plan lines for optimized efficiency 10% improvement in throughput resulting in 10% reduction in Cost per Piece Potential revenue gain of US$ 185,000 per annum Improved coordination between departments in production Development and establishment of Standard Operating Procedures (SOP) Elimination of Lost-Time 100% demand-based supply hit rate fom a baseline of 20% Zero Inventory level through Just in Time production, resulting in reduction of stock holding cost 30% Reduction in Cost per Piece Conversion of Double Shift Operation to Single Shift 45% Excess Space Identified resulting in Reduction of Outsourced Warehousing Charges US$ 185,000 savings in the first 12 months 10% by the 4th Month Project Payback in 3 Months US$ 350,000 Savings in the first 6 months 100% Hit Rate 30% Reduction in cost per piece Project Payback in 4 Months

4 Training & Certification Engagement Model Lean Six Sigma skills provide managers and operational staff with a scientific approach to viewing operations and process management. These training initiatives are designed to enhance the capabilities of the internal teams, serving as a platform for launching continuous improvement across the organization. Brandix i3 s trainers are business transformation & improvement specialists. They engage with trainees and mentor them throughout the execution of improvement projects which are a core component of the training. Training Programs Offered Lean Six Sigma White Belt Yellow Belt Green Belt Six Sigma Black Belt Lean Blue Belt Lean Yellow Belt Training Achievements Lean Six Sigma Green Belt More than 150 Candidates Problem Solving Techniques Advanced Process Basics of Process Awareness Sessions on Business for CXOs Lean Yellow Belt More than 300 Candidates Setting up Barrier Removal Teams (BRT) Identifying Process Barriers via Data Analysis Generating solution using Lean, Six Sigma, TPM and TCT Baseline Assessment Capturing and Validating Data Reviewing Current KPIs Understanding the Existing Process Data Analysis Implementing Solution using methodology Driving team towards achieving results Using Control Plans, and SOPs to sustain s Training on problem solving for Key Process owners as required Validating Financial metrics Six Sigma Black Belt More than 20 Candidates Lean Blue Belt More than 100 Candidates Assessing Baseline for KPIs Identifying Opportunities within Value Chain with KPIs using Six Sigma 130+ Process Excellence Engagements 85% of Engagements Resulting in Repeat Assignments 50+ Years of Combined Core Team Experience 500+ Aspirants Trained in Lean & Six Sigma Diagnostic Study Scoping Business Process Challenges Identifying Areas for Helping to Identify True Business Operating Potential

5 Why Brandix i3? Contact Us Passion for customer value with disciplined delivery, focused on results Specialists with hands-on industry and functional experience Ambitious vision for growth with a 200 strong team in US, Australia and Sri Lanka Financial stability and continuity - part of the US$ 700M Brandix conglomerate US 221, 1st Ave SW, Suite 203, Rochester, MN 55902, USA. +1 (507) Sri Lanka 146, Kynsey Road, Colombo 7, Sri Lanka Australia Level 10, 313 La Trobe St, Melbourne,Vic, Global engagement experience across United States, Mexico, Russia, Pakistan, India, Sri Lanka, Bangladesh, Malaysia, Singapore and Australia Copyright 2014 Brandix i3. All rights reserved. The word and design marks set forth herein are trademarks and/or registered trademarks of Brandix i3 and/or related affiliates and subsidiaries. All other trademarks listed herein are the property of their respective owners. This document is provided for informational purposes only and does not constitute a commitment to you in any way. The information, products and services described herein are subject to change at any time without notice.