Manufacturing Excellence
Manufacturing excellence is the cornerstone of a successful manufacturing strategy, requiring a comprehensive approach that integrates operational efficiency, quality assurance, and innovation. Central to this strategy is the optimization of processes to minimize waste, reduce lead times, and enhance productivity. This entails adopting lean principles, continuous improvement methodologies, and advanced manufacturing technologies to streamline operations and maximize resource utilization. Quality management systems play a pivotal role, ensuring consistency, reliability, and adherence to standards throughout the production process. Embracing a culture of innovation fosters agility and responsiveness, empowering teams to identify and implement novel approaches for enhanced product performance and customer satisfaction. Moreover, effective supply chain integration and collaboration further bolster manufacturing excellence by optimizing inventory levels, mitigating risks, and enhancing flexibility to meet evolving market demands. By prioritizing manufacturing excellence within their strategy, organizations can achieve sustainable competitive advantage and drive long-term growth and profitability.
We have a comprehensive methodology for manufacturing strategy development focused on 6 key pillars:

Analyze Manufacturing Network Structure
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Manufacturing Footprint
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Number of plants
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Regions/countries plants where are located
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Total square footage, total headcount
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Plant Profiles
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Product assignment to plants
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Horizontal vs. vertical network
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Economies of Scale
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Optimal plant size, number of lines/facility
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Process Flows and Manufacturing Families
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Processing steps from raw material to finish goods, manufacturing families
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Production System Choice
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Job shop/ batch flow/ operator-paced line flow/ equipment-paced line flow/ continuous flow/ just-in-time/ flexible manufacturing system
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Make-to-stock/ make-to-order/ assemble-to-order
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Plant Layout and Material Flows
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Process-driven vs. product-driven, line/cell shape, material flows
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Analyze Supply Chain Structure
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​Vertical Integration Model
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Elements in the supply chain, value stream
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Cost benefit analysis
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Qualitative analysis
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Make vs. Buy Alternatives
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Cost benefit analysis
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Qualitative analysis
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Risk assessment
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Supply Market Alternatives
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Key evaluation criteria for supply markets
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Number and location of potential supply markets
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Supply market analysis
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Procurement Strategies
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Partnerships
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Reverse auctions
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LCC sourcing
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Analyze Distribution Network Structure
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Channel Strategy​
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Number and types of channels
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Number of channel members: Zero, one or two
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Channel structure: Conventional or free flow; Single transaction; Vertical marketing system
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Channel decision-making structure
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Network Model
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Number and location of customers (demand forecast)
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Target service level
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Number and location of production facilities, distribution centers, and warehouses
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Logistics cost
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Distribution strategy – static vs. dynamic; centralized vs. decentralized
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Transportation/ Warehousing Cost Model
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Available modes of transportation and relative costs
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Number, size and location of warehouses
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Inventory management costs
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Distribution System Performance
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On-time delivery
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Customer service levels
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Analyze Distribution Network Structure
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Channel Strategy​
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Number and types of channels
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Number of channel members: Zero, one or two
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Channel structure: Conventional or free flow; Single transaction; Vertical marketing system
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Channel decision-making structure
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Network Model
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Number and location of customers (demand forecast)
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Target service level
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Number and location of production facilities, distribution centers, and warehouses
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Logistics cost
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Distribution strategy – static vs. dynamic; centralized vs. decentralized
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Transportation/ Warehousing Cost Model
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Available modes of transportation and relative costs
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Number, size and location of warehouses
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Inventory management costs
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Distribution System Performance
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On-time delivery
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Customer service levels
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