MTG worked with a leading window manufacturer based in Chicago. The window manufacturer holds a strong market position in the window industry, and runs an overseas manufacturing unit in China.
As MTG started the consultation with the window manufacturer, we found that they faced the following challenges:
The window manufacturer faced operational inefficiencies, which ultimately impacted their window production output
The window manufacturer faced quality control issues which compromised their product standards and market reputation
The window manufacturer faced financial issues, which were exacerbated by COVID-19. It was also difficult for them to manage the overseas facility while maintaining profitability.
Once MTG assessed the factory floor of the window manufacturer, we identified the points of friction that was leading to low production efficiencies. We discovered that Overall Equipment Effectiveness (OEE) was at 40%, which is considered very low. Additionally, we found that inventory and work in progress wasn't optimized, leading to poor production efficiencies.
We chose to integrate the people and the processes of the window manufacturer together, to seek out solutions and address the manufacturers difficulties.
We first conducted comprehensive assessments to identify the root causes of each and every inefficiency. We also addressed each crucial bottleneck in the welding stage by redesigning the production line and rearranging the equipment. Finally, we implemented employee training programs for the new production setup.
