Business Re-Design Process for a Leading Glass Lined and Chemical Process Equipment Manufacturer

Automotive Consulting Firms

Client Challenge

The client was a leading manufacturer of glass-lined reactors and other chemical process equipment has a manufacturing facility in Gujarat. The issues faced by the client with the current IT system included:

  • Lack of planning functionality in the system
  • Existing system was too slow thus resulted in people avoiding the system for data entry
  • Reliability of information generated was low
  • Regular changes in the functionality reduced the integrity of the system
  • The existing system was custom made and hence upgrades in technology and functionality was unavailable

UC Strategy assisted them in the business process re-design part of the IT implementation.

Our Approach

UC Strategy undertook the steps below for the business process re-design of the chemical process equipment manufacturer:

  • Understood the various processes including the following –
    • Manufacturing of various items
    • Procurement of various raw materials, components and sub-contracted items
    • Issue of raw materials, components, consumables from stores to shop floor
    • Customer order booking, tracking and dispatch
    • Collection and other accounting processes etc.
  • Assisted clients in the business process re-design phase of the project, including –
    • Re-designing the procurement planning process including that of items like forging and steel, having very long lead time. UC Strategy identified a planning method for each of these items as per their procurement/ processing lead time and consumption pattern and defined the re-order point where required
    • Re-designed the manufacturing planning process to reduce the manufacturing lead time using the power of postponement concept, enabling the planning and production team to track manufacturing, and plan the availability of work centers and the manpower
      • Defined the levels and activity in the BOM
      • Define the work centers
      • Capturing the lead time for various activities according to the size of various equipment manufactured
    • Re-designed the sales and after-sales services to ensure maintaining the history of each equipment manufactured
    • Re-designed the materials receipt process and it’s inter-linkage with the accounts payable process, to eliminate the need to print the good receipt notes (GRN)
    • Assisted in finalising the item code allocation process through the system
  • Assisted the client team members, defining the inter-departmental interactions and other decisions regarding the masters/ structures in the system
  • Also assisted the client in defining the company structure in the new system

Our Impact

UC Strategy assisted the company through the business re-design process and managed with speedy execution.

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