We currently are supporting >99% on time shipments to our original schedule. This has been possible due to the following actions taken over the past few quarters:
Turnkey % increase
Dual sourcing
Building a learning organization
Turnkey: If a device can be assembled, tested and finished in a single location, we call it a turnkey capable device. We currently have >83% of our volume as turnkey. Doing this has helped us reduce our overall cycle time by cutting out the transit times involved.
Dual sourcing: A device needs to be qualified to run at least at two sites for every activity to be considered as dual sourced. We currently have >90% of our devices dual sourced. This has insured our supplies against any capacity issues at any one site.
Building a learning organization:The learning of the team over the years is now being locked down and documented. All new hires are needed to study and clear a certification program before getting hands-on for the job to ensure that, no manual error affects our customers.
We have also simplified our manufacturing process over the last two years. In 2010, we had 31 manufacturing locations and 211 shipping routes, we now have only 18 manufacturing sites and 48 shipping routes. This simplification allows for more predictable outputs and significantly shorter cycle times.