How a global luxury company improved its volumes by 60%

Our Client is a leading global player in luxury fashion and leather goods.

Business Challenge

Following the construction of a new plant, the client needed to internalize specific activities related to material flow optimization and handling on assembly lines. To overcome this challenge, this was our approach:

Analyzed the current situation to understand the design and functioning of the current preparation area. The goal was to gain insights into the current processes and identify areas for improvement.

With this understanding, we then studied the ideal logic and sizing of the flow between the warehouse and the preparation department

Real-World Testing: Finally, we tested the chosen solution within the actual factory environment. The aim was to validate its effectiveness and fine-tune any adjustments needed for seamless operations.

Approach

The project included the following steps:

Logistics
- Developed a new Kanban logistics system for material handling and recall, by introducing standardized trolleys and boxes.
- Introduced a system of trolleys of product components to be worked on with available materials in the "frozen period"
Improved layout of the new plant – production area
- Analyzed the current preparation area, evaluating various scenarios for department organization using specific tools such as spaghetti chart, from-to matrix, saturation machine
KPI
- Defined and introduced an indicator system related to Productivity, Quality, Safety
- Indicator “totem” introduction (PCS System) on the assembly and preparation area

Results

Stabilized, standardized material flow from warehouse to/vs depts
Reduced stopped orders due to lack of material
Improved new plant’s layout
New macro layout of machines and tools in preparation and paint areas, optimizing operator movements and machines’ utilization rate
60% volumes
Cost benefit ratio: 1/3