Manufacturing - Challenge Advisory

Industry Practices - Manufacturing

Maintaining high quality and low costs is crucial for manufacturing businesses today.

Challenge Advisory’s Supply Chain and Manufacturing Operations practice is a leader in helping companies integrate business strategy with supply chain initiatives to drive operational excellence.

We employ programmatic approaches, leverage analytics capabilities, and offer managed services that can help improve top-line growth, lower costs, reduce response times and increase productivity.

Challenge Advisory draw from deep expertise and experience, thanks to a wide range of contacts in the manufacturing industry, ensuring that clients receive optimal solutions that are practical in the short term and sustainable in the long term.

 

The roots of poor quality and low manufacturing productivity often can be traced back to processes that happen long before the product hits the shop floor. They begin with product line complexity, product design, scheduling and sourcing.

Manufacturers are often in the business of balancing trade-offs: revenue enhancement and cost containment; customization and standardization; and competition and collaboration. What’s new? The ever increasing complexity in which strategies are decided, plans implemented, and decisions made.

While our approach varies depending on the client’s situation, our overall framework starts addressing strategic questions that impact production cost, quality, flexibility, service levels, and control. This includes a clear understanding of what is the current and future product portfolio, what should the company “make vs buy” based on core capabilities and needs, and what should the future footprint and capacity plan look like–including which sites should be closed, consolidated, or prioritized for optimization.

Balancing resources and budget efficiently in the face of ever-tightening guidelines can prove to be a difficult task, but Challenge Advisory provides proven techniques for improving manufacturing operation – including lean and Sixth Sigma – to vastly improve productivity and logistics in an industrial setting.

Challenge Advisory helps clients to adapt to the extraordinary pressures of the product manufacturing environment by offering extensive research, system models and strategic advice to enable our clients to plan strategies effectively, taking into account technological and logistical trends.

Challenge Advisory’s broad-based diagnostic method, which include comparisons with best practices and assessments of the potential of lean manufacturing techniques, identify changes that will reap the largest payoffs and the best methods of achieving them. We then help clients implement improvements, ranging from product line complexity reduction to manufacturing practices that dramatically enhance productivity.

Challenge Advisory has deep knowledge of the ins and outs of manufacturing, thanks to over fifty years of collective experience between their six functional teams (organisation, risk, strategy, new market entry, business development and sustainability) to assist any industrial client with performance and value optimisation, as well as risk minimisation.

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Technology and Innovation - Challenge Advisory's technology consulting services help you realise value from your technology. Our experts work closely with you to deliver technology-rich programmes.

Performance Excellence - Supported by our capabilities in technology and innovation, global supply chain and production, Challenge Advisory strive to cover all dimensions of manufacturing performance to maximise the benefits we can deliver to our clients.

Procurement and Supply Chain - We help you create exceptional results through innovative procurement and achieve competitive advantage by transforming the supply chain, ensuring procurement and supply chain leaders respond effectively for lasting success.

Procurement and Supply Chain - We help you create exceptional results through innovative procurement and achieve competitive advantage by transforming the supply chain, ensuring procurement and supply chain leaders respond effectively for lasting success.

Product Design and Development - Challenge Advisory's expert technology team helps clients to design and develop new products across a broad range of sectors including healthcare, communications, consumer products and defence.

Cost-Benefit Analysis - Challenge Advisory gives your purchasing, cost engineering and development teams timely access to the comparative data and costing tools they need to develop competitively priced vehicles, achieve significant savings with minimal risk.

The Automotive Industry

The global automotive industry used to produce more than 60 million vehicles annually. Although this figure has reduced to 50 million during recent turmoil, it still accounts for 5% of the world’s manufacturing employment. However, the competitive landscape is getting more congested. The kind of challenges now facing the automotive market have not been seen for over 20 years. The industry will change forever – in terms of leading markets as well as major players.

Previously automotive manufacturers had competed fiercely against each other, and had rigid structures and were protected by high market entry barriers. With Asian car makers aggressively growing market share, and emerging markets challenging traditional cost structures, suppliers and manufacturers needed to continually focus on lean and cost-effective processes and products.

They also had to focus on industry collaboration – while still delivering breakthrough innovation. Now they face a different kind of threat from new players – requiring new strategic alignments and an ability to capture value much further downstream than before.

 

Consumer Products

The news from the main players shows that the economic turmoil is hitting the engineering sector quite hard – which is seeing the start of a similar crisis to that faced by the automotive sector. Engineering companies will probably feel the downturn at different points in time but although the profile and length of the crisis is unclear – everyone needs to act now. This is true whether they are total solution integrators, solution designers, systems / machinery or component and part manufacturers.

Every crisis creates new winners – followed by a consolidation phase of M&A and take over activities for strategic assets. The winners in engineering will be characterised by unique technology innovation and a strong cash position. They will also have proximity to global demand and industrial trends, high market share in speciality areas or an excellent low cost position.

In addition they will need effective working capital management, reliable exchange of order schedules to both customers and suppliers; a customer-driven supply chain; lean product design based on standard modules; end-to-end requirements and claims management, and a high share in service business.

 

Our Partners

Challenge Advisory's Manufacturing practice allows for exceptional results with lasting impact through encompassing alignment of strategy, top-line and revenue improvement.

Our Partners

The Automotive Industry - Our experience includes helping European, American and Asian car manufacturers transform their organisations from R&D and purchasing to operations and sales.

Consumer Products - We help clients to develop consumer products from initial research and concept design, through development, prototyping, manufacture, supply chain set-up and support.

General Industry/Industrial Engineering - Challenge Advisory allows for industrial engineers to build a performance schedule that can be managed rigidly, focusing their portfolios and securing the cash position. Our strong execution will both deliver quick wins in the short term and more complex solutions in the medium to long term for our industrial clients.

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Sustainability

Many manufacturing institutes will benefit from the ability to prioritize sustainability activities and employ strategies to understand where program investments should be focused on capturing value.

Reduced materials cost and price volatility to help drive profitability and increase competitive edge. Supply chain improvements, including significant savings in manufacturing and sourcing costs, as well as product quality enhancements that can contribute to increased market share and improved margins.

An improved supply chain transparency that can help reduce risk for social issues around human rights, labor rights, and anticorruption issues. Sustainability initiatives drive business value in multiple ways through revenue enhancement, cost reduction, and risk management.

 

Smart Manufacturing

As intricate as a spider’s web, logistics and distribution networks are highly complex, making the movement of products and materials from point to point on a global scale a significant challenge for many companies. We bring a range of proprietary tools and a wealth of experience to help public-sector clients address this challenge, in particular in the areas of organizational design, human capital, organizational diagnostics, and transformational change.

To support preventative and predictive maintenance, Smart Manufacturing provides predictive models to analyze equipment performance and reliability. It enables manufacturers of complex products to offer their customers predictive maintenance services that reduce equipment downtime, unplanned maintenance and overall costs. Smart Manufacturing also includes specialized, preconfigured and user-configurable dashboards and reports, giving your facility, supply and service managers the information they need to optimize processes essential to meeting market demands and reducing costs.

 

Digital Transformation

Moving to an as-a-service IT environment can unlock capital investments tied to maintaining your legacy environment and enable you to reinvest in next-generation technologies. This foundation of cloud, apps, mobile technology, big data and even social media can enable manufacturers to introduce more innovative products and services – enabling new business models based on bundled costs and consumption-based pricing.

Challenge Advisory’s Digital Transformation solution helps manufacturers create a real-time digital enterprise with as-a-service infrastructure, modernized applications and best-in-class cybersecurity services.

With modernized applications, IT organizations are making major shifts in infrastructure investments by moving to a private, public or hybrid cloud environment. Not only are manufacturers accessing computing capacity based on usage, but also accelerating the entire process of application development, testing and maintenance.

Our workplace services support enterprise mail, unified communications, business and social collaboration virtual desktop, enterprise mobility, and mobile content management. Challenge Advisory can combine these collaboration services with analytics tools to provide management teams with fully integrated dashboards featuring real-time data to improve decision making and provide insights that can dramatically improve business outcomes.

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