The question is the answer.™
Our Clients
Client Case Studies
| Client: Monroe Table Company Industry: Manufacturing-Folding Banquet Tables |
|
Objectives:
To be more reliable in due-date performance, reduce production
cycle-time and improve gross margin. Monroe had become stagnant in an
industry that was finding ways to perform better. Monroe wanted to find
a new system of production that would allow the company to more
predictably deliver its goods to its market.
Work Services:
WHY! implemented TOC based Drum-Buffer-Rope (DBR) method of
manufacturing and developed an order board so that the customer service
associates could provide a reliable due date to their clients at the
time of order. Monroe is an A-Plant where orders go through a central
assembly point that combines the wood tops with the metal legs. A 5-day
rope length was set and a system to produce travelers was built and
customized to ensure plant-wide synchronization.
Results:
- Due date performance moved from 80 to 98%.
- Order lead time went from 4 to 2 weeks.
- WIP drained in 90 days to produce significant cash.
- Gross Margin increase.
| We built and utilized the DBR
production system to improve our manufacturing performance,
improve our customer delight and improve profitability. I'm happy
to report that we were able to do all three and synchronize our
plant to the demands of the market. Mark was a real champion of
the DBR process before, during and after its installation - and
contributed greatly to its success. Bill Colville, General Manager |
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