Manufacturing & Assembly
Case Study 1 - MRO Facility - Laptop repair
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Low Customer Satisfaction - TAT not at target
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High stress operation
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Low/No margin
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Strategy to close operation and exit country for cheaper alternative
Creating flow to save the business
A high-mix product environment with variable demand was creating service issues and high operating costs — overtime, inventory burden, staff turnover, and penalties were eroding margins.
Customers were dissatisfied, and without change, the business was at risk.
We implemented lean-based solutions, including a cell-based layout, redistributed workflow, and kanban material controls to reduce inventory. These changes significantly improved service levels and gross margin, safeguarded jobs, and became the benchmark for laptop repair internationally.
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Finance
Turnaround from loss making business to +20% Margin
Speed
80% Reduction in Turnaround time to Customers
Quality
63% Inventory burden to company reduced and maintained
Morale
Improved staff retention through upskilling and ownership
Benefits