Tag: manufacturing

FORTUNE: CEO Turnover Hits 5-Year High as Companies Brace for Continued Disruption CEOs are passing the torch after guiding their companies through the worst of the pandemic

Don’t Wait for a Crisis
Fortune: CEOs are passing the torch

CEO turnover recently hit a 5-year high as organizations brace for continued disruption. In Kormac's executive collaborations, we've certainly seen many leaders heading for the exits. We've also noticed a disturbing trend of executives reaching out to us far too late. When leaders are struggling with operational challenges, some belatedly...
Global Packaging Machine Shop Optimization Demand for production machines quadrupled as post-pandemic conditions limited supply availability. 390% growth Improved shop floor forecasting, utilization, management tools, and communications Developed effective systems to support on-time delivery performance, transparency, and growth capacity.

Global Packaging
Machine Shop Optimization

If your recycling bins are fuller than they used to be, you’re not alone. Macroeconomic and social trends are driving growth in the packaging sector, including enhanced sustainability expectations and increasing consumer reliance on e-commerce. Manufacturers of boxes, cans, pouches, plastic containers, tubes, cartridges, rolls, and more are grappling with the associated...
Manufacturing Inventory Reduction: Achieved Elusive Inventory Management Target Implemented global best practices; achieved corporate inventory target for the first time in 7 years.

Manufacturing Inventory Reduction
Achieved Elusive Inventory Management Target

To improve cash flow while mitigating risk, many companies are reevaluating their approach to inventory management. Excess materials and persistent shortages remain despite the overall recovery from pandemic constraints. When times were tough, gaps in inventory management discipline magnified the impact of constrained supply chains. As conditions improve, discipline gaps still leave...
Nearshoring to Mexico Nearshoring: ¡Vamos a México! Driven by federal incentives, geopolitical risk, and pandemic aftershocks, restoring and nearshoring continue apace. [Screenshots of various article titles about restoring and México] Kormac's senior operational experts have diverse experience designing, launching, and operating manufacturing facilities south of the border

Nearshoring to Mexico
Nearshoring: ¡Vamos a México!

Driven by federal incentives, geopolitical risk and pandemic aftershocks, reshoring and nearshoring continue apace. For manufacturers compressing supply chains, nearshoring to our southern neighbor provides a comfortable, cost-effective option. Companies of all size are feeling the pull – even 88% of small and medium sized businesses are “reshuffling their supply...
Interim Leadership Transforming a Plant as Interim GM When an integrated contract manufacturer lost its GM, Kormac provided a skilled interim leader Client Gratitude: Farewell messages to Kormac GM from dozens of plant employees [overlayed on top of image of the letters] On site for 10 months, our interim GM dramatically improved plant performance and morale

Interim Leadership
Transforming a Plant as Interim GM

We all lose our heads sometimes, but it’s big trouble if a factory does. When a leading manufacturer of aerospace fabricated assemblies lost its facility general manager, executives knew it could take months to find a qualified replacement. Unfortunately, their 50,000-square-foot integrated contract manufacturing facility needed a leader immediately. Kormac...
Manufacturing Facilities Optimization: Detailed Plant Scenarios and Modeling - Reduced manpoower requirements by 33%, cut warehouse overtime, and optimized off-site storage locations

Manufacturing Facilities Optimization: Detailed Plant Scenarios and Modeling
Reduced manpower requirements by 33%, cut warehouse overtime, and optimized off-site storage locations

As US manufacturers consider reshoring, they’re often prompted to reevaluate the configuration of existing facilities, including storage. We help such leaders develop detailed plant scenarios and models to guide recommendations on combining, consolidating, redesigning, and/or automating plants, including estimated costs and savings for each scenario. To follow is a chemical...
Assembly Magazine. October 19, 2022 by Harry Moser Geopolitical Forces Drive Record-Breaking Reshoring

Record-Breaking Reshoring
Geopolitical forces drive record breaking

𝗥𝗲𝘀𝗵𝗼𝗿𝗶𝗻𝗴: “Geopolitical risk and the advantages of domestic manufacturing are motivating more and more companies to move production back to the U.S., driving job announcements to record-breaking highs.” Assembly Magazine’s October assessment reflects our own experience: reshoring’s proximity to end-use customers provides compelling relief from logistical issues, risks, and costs....
Automotive Aftermarket Maximizing Throughput and Flow Kormac helped a leading manufacturer of truck caps, covers, and cargo systems to achieve: - 50% throughput improvement - 32% labor content reduction - Quality: right first time enhancement "Kormac found innovative and cost-effective solutions that improved Right First Time quality, throughput, and employee morale." - Client CEO

Automotive Aftermarket
Maximizing Throughput and Flow

A leading automotive aftermarket manufacturer was facing large impending order volumes and turned to Kormac for help in improving throughput, quality, and facility flow. Together, we developed a future vision for one-piece flow through their entire operation. Because new equipment proved cost prohibitive, Kormac and the client team sought to...
Cost Management Rebalancing the margin tug-of-war Does your organization struggle to achieve financial goals in an increasingly volatile marketplace? [iconography of two teams playing tug of war, with the target margin in the middle. Text above the image reads "Kormac Rebalancing"] Cost Pressures: Labor, Materials, Logistics, Real estate, Technolgy Market Pressures: Pricing, service delivery, quality, lead time, social responsibility Kormac's Surgival Strike Methodology™ delivers the agility you need to meet your financial objectivers.

Cost Management
Rebalancing the margin tug-of-war

As the labor and supply cost rollercoaster continues, we are working with several clients to identify new management levers. Among them: Increasing the frequency of cost reviews to ensure faster customer price adjustments and/or tying customer pricing to component market indices Executing Value Analysis and Value Engineering efforts to drive...
Lean Liberation Lean as Resource Liberator Sample Kormac Lean project outcomes - -50-60% cycle time reduction - -50% WIP inventory reduction - -85% cost of poor quality reduction - +30+% improvement in labor efficiency - +30+% EBITDA improvement - +20+% useable floorspace expansion - Overall improvements in safety performance and employee satisfaction

Lean Liberation
Lean as Resource Liberator

As manufacturers grapple with rising material and labor costs, we’re seeing renewed interest in Lean. Kormac has decades of experience in employing Lean/Six Sigma/Kaizen methodologies to boost quality, productivity, and speed while reducing cost, backlog, and facility floor space. We begin each Lean engagement by analyzing our client’s product line...