Improving delivery performance in pump assembly

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Lean approach for higher on-time delivery and productivity

An international pump manufacturer was under pressure: low on-time delivery, long throughput times, and high logistics costs. An interim operations manager established lean structures, Kanban, and new planning processes. The result: significantly improved delivery performance and increased productivity.

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Company

International machinery group and producer specialising in industrial pumps
European manufacturing footprint with central site for a hydraulic product line
Revenue > €8m, > 20.000 employees

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Challenge

Poor on-time delivery performance for pumps (50% OTD) and spare parts (70% OTD)
Long lead times in assembly and parts supply
Inefficient warehouse and logistics processes with high picking effort

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Goals

Clearly improve delivery performance for complete units and spare parts
Significantly shorten lead times in assembly and logistics
Build a lean, transparently managed supply chain

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Measures

Lean trainings, Kaizen workshops and layout rules in assembly and logistics
Kanban and two-bin system for small parts, reorganization of warehouse and packaging
Workplace optimization, one-piece flow, daily replenishment based on pull principle
Redefined planning process, shopfloor boards, rollout of new warehouse and logistics software

x

Results

On-time delivery for the hydraulic line improved strongly, target level of 95% OTD exceeded
Throughput times for pumps halved to 4 weeks, reduced from 7.2 to 2.6 weeks for spare parts
Productivity in assembly increased, picking effort clearly reduced
Logistics software successfully implemented across multiple areas, stable operations achieved

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