Project background: The client company is specializing in the development, design, production and sales of desktop and floor-standing power tools. It began to produce fitness equipment such as treadmills in 2018 and has become a supplier of well-known fitness equipment brand in the United States. In 2019, customer orders increased sharply. However, there are many quality and delivery issues with the treadmill products that have been put on the market. In order to solve the urgent problems and support the growth of the new business, with the strong request from the customer, the American LHC consulting Company was invited to appoint consultant Tim Zhang to lead this lean transition and quality improvement consulting project. Challenges: The rushed product development caused many potential problems escaped to shopfloor without robust developing process and an effecti...
Project background This is a multinational company specializing in the design and manufacture of cables and wire harnesses for computers and mobile phones. The main processes are injection molding and assembly. In order to promote business development and achieve simultaneous growth in production capacity, quality and efficiency in the short term, the group headquarters has signed a contract with a consulting company to establish and implement a lean manufacturing system Challenges Due to the continuous growth of its major client Apple Computer's business and a sharp increase in sales, the factory is facing huge challenges including of insufficient production capacity, timely delivery and quality improvement. Apple has put forward a strict requirement of zero defects for its products. It is urgent to build a renovated model production line (with capacity target of 6K per day) ...
Project background This is an international precision vacuum pump developer and manufacturer. The group's products are widely used in fields such as power, glass coating, metallurgy, pharmaceuticals, and chemical industries. Since its establishment in Qingdao High tech Zone in 2012. The factory introduced lean manufacturing system consulting services from the beginning of the new factory construction in 2014. Since then, its market share has continued to expand, forming a complete industrial chain and technical team from technology research and development, precision manufacturing to assembly and testing. Its products dominate and lead the high-end vacuum pump market. In 2016, the output value was 220 million yuan, and in 2017 it reached 400 million yuan. ...
Project Background This is a listed company specializing in the development, design, production, and sales of mobile phone series connectors, shields, ultra precision hardware terminals, and ultra precision molds. Due to the strong demand in the smartphone market, the company is in a period of rapid expansion. However, due to weak management foundation, many problems have arisen, with a first-time pass rate of less than 50% and on-time delivery of less than 80%. The factory is struggling to maintain high costs and pressure. Therefore, the new CEO has decided to embark on a journey of lean transformation. Challenges Traditional and extensive production management methods lack effective communication and collaboration among departments, there is no effective key performance measurement system, various management foundations are not yet sound, no clear work standards, management...
Project Background Since entering the Asian market, this brand has quickly gained popularity among Asians due to the diversity and superior performance of its products. Its product sales have grown rapidly, However, the traditional batch manufacturing method is obviously not suitable for the market demand of multiple varieties and small batches. Therefore, the group began to carry out global supply chain management optimization and implement customized lean manufacturing system in its own and ODM/OEM supplier factories. Challenges Although sales are growing rapidly, especially in the Chinese market. However, Taiwan's ODM/OEM supplier factories at that time followed the traditional mass production method, which was not suitable for the market demand of a wide variety of products and small batches. Most of the middle-level and above management leaders in the...
Project Background A large multinational company in Germany, mainly engaged in the production of shoes and sportswear. The vast majority of its sports shoe manufacturers are in China. Due to the increase in labor costs in mainland China, the group company has begun to seek ways to reduce costs and improve competitiveness Starting from the end of 2010, the group invited a consulting company to design a lean manufacturing method tailored to the characteristics of the footwear industry, and began to vigorously promote it in manufacturing factories in Asia; Lean consultant Tim Zhang led lean training and on-site improvement activities for two factories in Dongguan and Hunan, and participated in improvement activities for a factory in Vietnam. Challenge These Taiwan owned factories follow the traditional batch production mode. The on-site personnel lack training about lean...
Project background The company is a wholly-owned subsidiary of a Fortune 500 group and the first factory independently invested and built by the group in China. It has a total investment of 500 million yuan, covers an area of 110000 square meters, and has 5-6 well-equipped production lines with an annual output of 700000 tons. Core pain points The factory is located in Longmen County. Due to its geographical location, it is difficult to retain management talents, and the domestic production equipment is outdated. The manufacturing process is unstable, and the factory faces dual challenges of quality and efficiency issues. ...
Project background This dairy company entered the Chinese market in 1995. Then it is one of the main infant milk powder brands in the Asia-Pacific region. After the Sanlu milk powder incident in 2009, the government imposed various monitoring and control requirements on all milk powder companies. This brand was also compelled to conduct 60 or more mandatory inspections for each batch of products within 24 hours. The demand for imported high-quality milk powder in the Chinese market has increased dramatically, presenting the company with unprecedented opportunities and challenges. Shanghai factory launched lean manufacturing system WCM in 2010, Through a three-year implementation and continuous improvement of the manufacturing system and became their global benchmarking factory....
Project Background A wholly-owned factory invested by a French multinational group company in the Tianjin Binhai Development Zone in 1997, with 12 series and over 50 varieties of cheese products. In order to increase production capacity to meet increased market demand. The corporate group decided to start the lean manufacturing project aimed at to improve product quality, machine and labor efficiency, speed up inventory turn and reduced the total production lead time. ...
