Solving the Customer Service vs. Profitability Challenge Through Flexible Manufacturing
Pelion Systems provides Lean Manufacturing Solutions that significantly reduce operating costs and cycle times and help manage the complexities associated with flexible manufacturing by providing concise and usable information for making better and faster strategic, financial, and tactical decisions in a rapidly changing business environment.
Unlike other Lean approaches, Pelion offers a complete modular “pull” solution that increases manufacturing efficiency from final product shipment back through to supplier delivery. This allows our customers to make dramatic reductions in labor and inventory costs while successfully meeting the most demanding customer service requirements.
Pelion’s total Lean Manufacturing Solution includes expert business and technical consulting, an integrated Lean Manufacturing Operating System, as well as individual workbench applications that address the following needs:
- Dynamic Value Stream Mapping for characterizing plant processes as activities, connections, and flows
- Lean Engineering Workbench for mixed model cost analysis and lean factory layouts
- Lean Material Flow for reducing process inefficiencies
- Electronic Kanban for reducing inventory and improving supplier collaboration
- Lean Scheduling and Sequencing for maximizing delivery capability
- Lean OEE for organized Six Sigma improvement
- Visual Worksheets for operator effectiveness and performance management
Pelion’s technology and services have proven to deliver unprecedented value for manufacturers with complex operations, including a major automotive components supplier that has been able to validate annual savings of:
- $10 million, or 85% reduction in Premium Freight
- $20 million, or 75% reduction in Overtime
- $50 million working capital, or 40% reduction in Inventory
Pelion’s solution embraces and extends the value of existing ERP and SCM systems by creating a pull-based Lean operating environment that solves the flow challenges associated with flexible and mixed-model manufacturing, which traditional enterprise solutions and spreadsheets fall short of effectively addressing. Pelion also utilizes SCADA and MES data from plant floor systems to drive OEE and Six Sigma improvements.
The solution delivers a return on investment in four to six months and can scale from a single Lean engineer or production facility to an extended enterprise implementation. Pelion customers are applying best practice Lean principles that synchronize production, supply, and distribution to form a true demand-driven network.
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