Nelson Global Products

Tier 1 Operational Improvement Case Study

Tube Specialties (TSCO) part of Nelson Global Products, is a high volume tube manufacturer that produce product for the automotive vehicle market.

PROBLEM

As the demand for tubed product increased TSCO found their ability to meet customer delivery expectations was becoming challenging and they needed to focus on rapid internal improvement to not only ensure they met customer delivery targets but also to avoid any financial or profitability impact to the business.

SOLUTION

  • Deep dive diagnosis across entire organization
  • Immediate containments to problem areas
  • Mini-lighthouse program to ensure transformation
  • Visibility of activities throughout plant and at stakeholders
  • Develop internal agents to drive performance
  • Sensei approach (I do – we do – you do)
  • Elimination of Customer past dues
  • Reduce % of Labor Vs. Sales
  • Reduce % of Scrap Vs. Sales
  • Improve WIP and Finished Goods
  • Inventory turns
  • Reduce expedited freight of finished goods
  • Create production flow based on demand

RESULTS

  • Customer on time delivery increased 98%+
  • Operational cost reduction by 20%+
  • ROI – 10:1
  • Flexible manufacturing organization with designated standard work and process confirmations
  • Shop floor management including problem solving, displayed on information centres at all levels
  • Robust quality systems linked to shop floor management
  • Pull systems utilizing kanbans with defined inventory levels
  • Cell layouts optimized for flow, personnel and floor space
  • Structured scheduling and planning supported with PFEP