Mapping the current state of a production activity in order to improve the efficiency of operations

The customer's challenge

The customer's challenge

  • Lacked structured process library and did not follow described ways of working.
  • Low transparency and lack of information exchange between production departments
  • Lack of requirement specification when implementing a new ERP system
  • Lack of resources and time for both mapping and maintaining processes internally.

Systems before and after

Systems before and after

Two ERP solutions with financial management in both solutions (eBS onprem Oracle and Fusion which is cloud-based). System landscape with a lot of manual intervention to ensure that all systems have the information required for all functions to do their job. In the customer's case in this assignment, it was about shortcomings more than just the processes that existed in the ERP solutions, such as deviation management, the production chain and transport in the area.

The customer has not yet made any progress on how to change their application landscape to match how the organisation wants to work in the future. However, we know that improvement work is ongoing based on the GAPs that we identified during our process mapping.

Solution

Solution

At the client's site, we undertook a comprehensive process mapping exercise covering the following process areas: Deviations, Planning, Rework, Finance, Item Management, Transport/Logistics, Casting, Rolling and HR. To map all these areas, the client selected 34 business representatives to help us map their operations so that the results were as close to reality as possible.

If you want to read more about our agile process mapping and why our method works better than traditional process mapping, you can read more here.

Result

Result

After we finished the process mapping, we made an evaluation and heard what the representatives from production thought about the process mapping and their summarised results were as follows:

  • They were given a structured way to drive change.
  • Built understanding among employees about who does what and when it happens.
  • Significant opportunities for efficiency improvements
  • Described ways of working across current activities

Conclusions

Conclusions

Such an extensive process mapping provides a very comprehensive picture of the organisation's shortcomings, not only in the system support implemented but also in their manual routines/processes and communication between departments. Therefore, one conclusion we drew from this assignment was that it is not always only the system support that is lacking, but there are other factors that affect the business negatively.

We carry out at least 20 different assignments in parallel, which means that our experience bank is developing at a rapid pace. To give you inspiration for projects that can be similar to your current challenges, we share here what we have learnt from others that will benefit you in a future assignment.

What we have done