Case Study
From Daily Firefighting to Production Control
Client Type: Regulated Manufacturer
Engagement Length: 12 Weeks
Primary Challenge: Chronic Firefighting and Poor Schedule Stability
Outcome: Improved Production Control and Increased Effective Capacity
The Challenge
The client operated in a constant state of reactive planning. Production priorities changed daily, resulting in excess work in progress, frequent expediting and inconsistent delivery performance.
Management believed additional capacity would be required to improve results.
The assessment revealed that capacity was not the primary constraint. Planning rules, work order structures and scheduling methods had become disconnected from the way the factory actually operated.
Several manufacturing processes were being scheduled around immediate demand despite significant setup and changeover requirements.
Diagnostic Insight
Rather than increasing planning effort through additional administration, the focus was placed on creating a more structured and scalable production control system. The solution introduced improved work order architecture, product family-based scheduling, economic batch quantity planning and enhanced production visibility, supported by standardised production control processes. Together, these changes improved planning accuracy, reduced operational complexity and created a more predictable manufacturing environment.
Solution Developed
The programme combined process mapping, MRP optimisation, workflow redesign and planner training. Production controls were realigned with manufacturing reality, reducing disruption and improving schedule stability.
Implementation (12 Weeks)
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Improved schedule adherence
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Reduced firefighting
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Lower WIP levels
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Improved production visibility
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Reduced material handling effort
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Increased confidence in production plans
Business Impact
Operational Impact
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Increased effective production capacity
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Reduced operational waste
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Improved labour utilisation
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Deferred capital investment