• Large variety of SKUs, all made to order
• Process layout with high manufacturing lead-time
• Inventory levels far higher than competitors
• Large mismatched inventory
• High non-linearity in production
• High rejection and rework levels as compared with competitors
• Substantial amount of waste of steel-strip in the sintering process

ECS Approach:

• Implemented cellular layout - formation of 8 cells
• Three year demand planning for all SKUs
• Identification of MTO (Made to Order) and MTS (Made to Stock). And finalising minimum level and replenishment level for MTS items
• Improved the alignment between dispatch and production scheduling
• Waste in the entire product flow, in the form of rejection, rework, setup times, material loss identified and reduced through cross-functional teams.