End‑to‑End Manufacturing Visibility
Client type
Manufacturer with complex, high‑value production processes.
Challenge
A critical part of the manufacturing flow lacked visibility and shared understanding. Planning and execution were not aligned, replanning was frequent and time‑consuming, and improvement initiatives often failed to gain traction across departments.
What we did
We mapped and visualised the actual production flow for key assembly steps using planning data, historical outcomes, and quality data. By combining data science, interviews, and hands‑on workshops, we made it possible to see how effort, duration, and delays varied across the process. The work revealed where plans and outcomes diverged and surfaced the hidden trade‑offs driving delays and inefficiencies.
Results
The client gained a shared operational model that made planning gaps and friction points visible across teams. This created a foundation for coordinated improvements, helping departments align around reality rather than assumptions. The work also demonstrated how data can be used to shift from compromise‑driven planning to outcome‑oriented decision‑making.