Challenge

Industrial machinery caused ability to have high mix of products difficult

More effective coordination with departments, WIP, and raw materials was needed

Engineering lead-times for products needed to be reduced

Synchronization between sales, engineering, and production was needed to meet customer needs

Solution

To begin, we implemented visual production planning and started planning the capacity between the production and sales departments. SMED was introduced in order to lower machine setup times, thus allowing IMSA to achieve higher product mixes. From there, we developed and implemented electronic production planning and devised self-management systems to help the front-line staff make important operative decisions. This technology enabled IMSA to streamline all departments, including; Production, HR, Purchasing, Engineering, Maintenance, Laboratory, and Sales and Field Sales Engineers.

Results

With an amazing turnaround, IMSA’s manufacturing-shipping lead-time was reduced by 88%. All works-in-process consisting of copper, aluminum, and PVC was reduced by XX million USD in working capital.

In the Finished Goods Warehouse an increase in product mix is also evident. Products available for sale “SKUs” increased 19 times. This was achieved with no implementation of information systems, no new warehouses, no new personnel, and no new equipment.

Enna designed, developed, and implemented IMSA’s own customized ERP software to incorporate quoting, HR, quality, engineering, internal logistics information systems, and sales.  Today, IMSA is the number one producer of electrical cables and magnet wires in their industry.

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