Footwear industry – digital development
Company from the Marche region, manufacturer of plastic and EVA soles and shoes for luxury brands.
Acquired by a fund in 2019, it has launched an important development program, introducing new management, merging the three companies of the Group, implementing a new ERP system, Investing to increase production capacity with new molding machines and new spaces to extend assemblies and warehouse.
At the same time, it has sought to increase volumes, achieving a growth of more than 30% in 2021, but with enormous operational difficulties and a deterioration in the level of service to customers. The new procedures imposed by the new ERP have in fact proved impractical for the organization, unable to manage both change and increasing volumes.
At the beginning of 2022, the company needed to break the vicious circle that prevented regular order fulfillment and to regain effectiveness and efficiency, starting a path of reorganization and continuous improvement.
Activities and improvements
- ERP optimization to improve customer delivery times and control of inventory and material flow.
- Reorganization of production planning and inventory control activities.
- Strengthening the organization to improve skills and promote managerial culture.
- Structuring of the Operations team with the inclusion of new Purchasing and Quality and HSE Supply Chain Managers.
- New Industrial Footprint integrating a new factory dedicated to assembly lines and semi-finished goods warehouse
- Redefinition of the Audit Model and auditing accounting processes
- New KPI dashboard to monitor:
– Projects Product Development
– Customer Order Book and Service Level
– Output of production
– Production efficiency and yield
– Supplies, Work Account and Service Level
– Quality and stocks
- New MES solution for the moulding department
- New CMMS solution for mold management
- Improvement of assembly and packing activities and balancing maneuvers
- Standard time revision
Results
- ERP optimization
- New organization Operations and procedures for production planning and stock control
- New production layout and warehouses
- New Dashboard KPI Operative, MES stampings and CMMS mold management
- New control model
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