Transforming Efficiency Through Zero Loss for a Leading Asian Manufacturer
Case Study
Author: Kevin Ross | 2 minute read
The project utilized TPG’s Should Cost approach to develop a ‘zero loss’ Ideal State, focused on optimizing processes, empowering people, and minimizing material waste.
The Opportunity
In a highly competitive market, our client faced significant pressure to improve margins on high-volume products. A new approach was essential to unlock substantial cost-saving opportunities across their supply chain.
The Approach
- Complete waste awareness training that builds capability of all to understand Zero Loss’
- Develop an ideal state that eliminates all current waste, meets future business needs and leverages best in class automation and technology. Quantify the size of prize to achieve Ideal State.
- Develop a target state for the site. Align on all capabilities to achieve from a Labor, Equipment and Materials POV. Quantify savings.
- Develop an action plan to achieve Target State
The Outcome
TPG delivered 10 unique training programs to build capability.
Improved productivity by 30%, and reduced inventory by 30%.
Developed a target state with the local teams on a level that met or exceeded all business goals.
- Define – create an insights-informed, consumer-facing view of the category.
- Discover – synthesize key learning and implications from primary & secondary research, conduct interviews with key suppliers to identify areas of strength, vulnerability, and partnership potential.
- Develop – articulate an inspiring and galvanizing vision for the category, underpinned by a range of strategic growth drivers and supporting initiatives that will help deliver the growth ambition.
