Swiss-based speciality chemical producer, 110 employees, 2 facilities
The company faced a 19.2% rework rate for production batches, an average order fulfilment cycle of 34.7 days and overtime costs exceeding €190K annually.
We mapped 32 core processes using value stream analysis to pinpoint inefficiencies. By introducing a predictive quality control system with 93.4% defect detection accuracy, we helped the client proactively address quality issues. We also redesigned shift scheduling to reduce changeover time by 41.3% and implemented real-time performance tracking, empowering managers to make data-driven decisions. Our involvement ensured that process improvements were both practical and sustainable.
Rework rate dropped to 6.8% within 11 months
Fulfilment cycle shortened to 26.1 days
Overtime costs reduced by €62K annually
Scrap material costs decreased by 18.9%
