1. 2. 3. 4. 5. 6. 7.

The defect rate is about 15%; Employee turnover is large for the industry; On-time customer delivery service rates are poor; Cycle time is several weeks for a product whose run time is less than one hour; Customer complaints are up significantly; Inventory balance is over $1 million; Volume throughput is poor compared to competitors;

Draw the current value stream and value stream map for Malaysian plant; Determine value added and non value added activities; Reduce the non value added activities; Create a new value stream map adhering to the takt time; Organize the material flow (using cell design; providing buffers);

Identify the pacemaker process ; Decide on pull or push;

Implement ERP systems; Better forecasting; Information integration; Logistics management; Risk management;

Cycle Reduction

Shorter Lead Times More Customer responsiveness

Lower inventories are needed

As an consultant we would recommend to implement the described changes in the facility; Monitor them for next 6 months; Then, show the results obtained to the corporate office;