Manufacturing
Restructuring for Excellence
Production, stores and accounts each held a different version of the truth. We rebuilt the movement discipline that ties them together.
The challenge
Material moved on verbal instruction, job costs were reconstructed after the fact, and the annual count produced a write-off that had quietly become an expected line item.
What we did
Standardised every stock movement against a document trigger and a named owner.
Introduced bin-level locations and one unit-of-measure convention across sites.
Replaced the annual shutdown count with rolling cycle counts weighted by value and movement.
Routed each variance to a root cause, feeding the fix back into the process that caused it.