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CRITICAL BUSINESS ISSUE: Senior Management approved a cost reduction proposal to shift overflow U.S. orders to one of the company's Southeast Asian facilities. Significant concerns arose on technology transfer and integration. Over $10 million in annual savings was projected. ACTION TAKEN: A special team of 30-50 in-house experts on Assembly, Shipping and Order Fulfillment, Sales, Accounting and others was formed. Supporting the team was a group of 6 Process Mapping, FMEA, and Program Management experts resourced by the company's Global Business Process Improvement team. In just 3 weeks of full time (and overtime) efforts, the sub-teams created over 80 Process Maps, conducted 120+ FMEAs and crafted control plans. The Asian-based members of the team returned to their site and within another 3 weeks created matching Maps and Control Plans. The resulting new line startup was the smoothest in the company's history and the projected savings are being realized. The model used for this project is now the standard practice for the company.
MASET, LLC
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