Lone Star’s simulation for a $30 billion asset acquisition cut costs, reduced scrap, and improved efficiency by optimizing WIP, capacity, and production cycle times.
The Issue
Our client managed an acquisition of $30 billion in highly complex assets.
The critical components to the program’s success are production delivery schedule, first-pass yield, and sustainment optimization.
However, their existing approach was behind schedule, over budget, and not meeting the necessary quality parameters.
The Solution
MaxUp® OPS Simulated Environment: Lone Star constructed a MaxUp® OPS simulation of the existing manufacturing and Tier 1 supply environment.
Process Analysis: Enabled the evaluation of work in process (WIP), capacity constraints, throughput, and cost of quality.
The Results
Improved Cash Flow: The MaxUp® OPS simulation optimized and minimized WIP, improving cash flow
Process Optimized: Optimized capacity and improved outlays for tooling and test equipment
Improved Cycle Times: Significantly lower rework and scrap rate with improvement in production cycle times
“What If” Evaluation: Evaluation of “virtual” changes prior to implementation.
