Manufacturing Transformation

Manufacturing Transformation

Reduce waste, improve capacity, and globally optimize constraints to reach your P&L and balance sheet goals with our unique offering.

Ready to Hit Something?

Effectively operating a manufacturing facility or enterprise while maximizing margins is extremely challenging. Pick your most pressing issue. Are you failing to meet your P&L and balance sheet goals? Or not reaching your production KPIs? Are your levels of material waste too high, your lead times too long, and your order fulfillment rates too low? Or perhaps you’re fed up with applying spot solutions that don’t deliver the full benefit.  Without evaluating your full value stream to define root cause issues, you can never  move your manufacturing facility to the “next level” of performance.

We hear you.

You’re tired of losing market share to competitors. You’re ready to hit something. And that something is better aligned goals. You’re ready to hit a new ratio on your return on assets, a healthier number on your product costs, a better score on your product quality.

You are ready, in other words, for a manufacturing transformation.

Introducing Manufacturing Transformation from MCA Connect

Manufacturing Transformation from MCA Connect is a unique service that helps manufacturers reduce waste, improve capacity, and globally optimize constraints to achieve P&L and balance sheet goals. It’s a comprehensive offering that reviews your goals, establishes objectives, uncovers opportunities for improvement, designs future state processes and leading edge IP solutions for transforming your manufacturing operations into an optimized “reaction ready” 4.0 facility.

Manufacturing Transformation is designed for manufacturers like you. Complex manufacturers who must make significant changes to their people, processes, and technology to meet their P&L and balance sheet goals.

For Manufacturing Transformation,
Take Five Steps

Manufacturing Transformation involves a strategic, logical, proven, and proprietary process that MCA Connect has perfected over the years. We guide you step by step through a five-stage transformation process that helps you realize the full potential of your manufacturing operation.

We base our recommendations on your unique business and objectives

Manufacturing Transformation involves five key stages. Each of these stages involves a number of steps and processes. Some of these steps will apply to your operation, and others will not. You may skip some of the steps in the diagram above while implementing other steps not listed there.

Customized engagement, tailored to your unique business and shop floor challenges and goals, is the key to your success with Manufacturing Transformation.

We Make a Difference Because We’re Different

To transform your manufacturing operations, you must implement changes. To implement those changes, you need a partner. And when it comes to manufacturing technology partners, you have four options.

Option 1

You Hire a Boutique Consultant

You hire a boutique firm that has expertise in process improvement but most likely lacks necessary expertise in workforce adoption, technology enablement, and technology implementation.

Option 1

You Hire a Global System Integrator

You hire a Global System Integrator that has expertise helping large, complex manufacturers, but lacks sufficient depth in the industry’s operational nuances, overcharging for strategy without real start to finish execution

Option 1

You Hire a Technology vendor

You approach a technology vendor that operates in your industry, but they lack depth of expertise in operational excellence and have a technology bias.

Option 1

You partner with us

You hire MCA Connect, the manufacturing-specialized consultancy that’s committed to helping you overcome your performance challenges to achieve operational excellence using your current technology with options for world class future state systems.

At MCA Connect, we’re cross-functional industry experts who understand business process and speak your language—the language of manufacturing.

We understand Microsoft Dynamics 365 and the complete Microsoft technology stack. And we are the unique technology partner that focuses on accelerating business outcomes, not just features and functions.

Our expertise is in helping manufacturers achieve continuous improvement and operational excellence. We leverage unique technology enablement and workforce adoption expertise in our Manufacturing Transformation solution.

Implement Manufacturing Transformation.
Realize superior performance.

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Optimize Efficiency

 

Increase OEE

Increase resource utilization

Reduce end-to-end lead time

Globally optimize constraints, both geographically and within
the entire plant

Optimize capacity by using tools and processes that increase
organizational capabilities around constraint management

Connect the value stream from the C-suite to the shop floor

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Maximize Profitability

 

Reduce cost of poor quality

Increase inventory turns/return on assets

Increase on-time and in-full shipment percentages

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Minimize Errors and Waste

 

Identify early signs of abnormalities before they cause issues

Minimize waste by eliminating activities that create minimal value

Eliminate silos between functions

Case Study

Company

Fortune 500 Manufacturer of Electronics Industry

Challenge

The manufacturer needed to transform operations from discrete manufacturing to lean manufacturing (in other words, transition from make-to-stock to make-to-order) because they couldn’t effectively manage significant spikes in demand at the end of each quarter. Their primary challenge was that materials did not flow efficiently throughout the manufacturing process. Also, the manufacturer could not shift product across manufacturing lines dynamically to make different products because their manufacturing lines were specific to each product line.

To meet the spikes in demand, the manufacturer had to:

  • Incur tremendous overtime costs from contract labor
  • Run two to three weeks into the next quarter to meet demand
  • Order excess materials before the anticipated spike to act as a buffer
  • Inflate WIP inventory to have partially completed product to meet anticipated demand

Solution

MCA Connect conducted a two-week Kaizan continuous improvement workshop, created current state and future state value stream maps, prioritized improvement opportunities using a Kaizen Opportunity Pick Chart, created an initial design for the new line, conducted a lean simulation within Microsoft Dynamics 365 to demonstrate how a lean process would work, built a pilot line, and trained the process engineering team.

Results

The manufacturer reduced its inventory from 19 queues down to 1 supermarket and 2 queues (each queue shorter than 1 day). They transitioned from make-to-stock to make-to-order manufacturing. They also transitioned from one line manufacturing one product using push manufacturing to one line manufacturing multiple products using lean manufacturing.

Client Success

“After implementing our analytics tools, we’ve been impressed that such large-scale business processes have not been impeded at all by performance issues. The system purrs like a kitten.”

Lonn Bate, Director of Information Systems

CES Energy Solutions

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“MCA Connect was instrumental in helping us value-stream our business. They understand all aspects of process flow, including people, machines and materials. They know Lean manufacturing and they know Dynamics.”

Bill Battershell, CFO

Rochester Gauges

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“MCA Connect feels like part of our team. Their consultants are great at what they do, very professional and organized, but also warm and friendly.”

Codi Nichols, Project Lead

Thermon

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