Cast Study: Global Prosthetic Manufacturer → VDS Consulting

Case Study:

Value Driven Solutions' Transformation of a Global Prosthetic Manufacturer

Client Overview:

Company: Global Prosthetic Manufacturer
Industry: Medical Devices (Non-invasive Orthopedics)
Specialization: Customized orthopedic solutions on a high mix, low volume basis

Project Overview:

Objective: To enhance operational efficiency and implement a just-in-time (JIT) production system tailored to a mixed model-custom business model.
Project Duration: 12 months

Challenge

The client, a global leader in non-invasive orthopedics, faced operational inefficiencies and challenges in managing their high mix, low volume production environment. The need for a strategic overhaul was critical to reduce costs and improve production timelines.

Solutions:

VDS Business System® Implementation:
- Introduced and implemented the VDS Business System®, a comprehensive operational excellence framework tailored to the client's specific manufacturing model.
- Focused on streamlining production processes and implementing JIT methodologies to enhance responsiveness and reduce waste.
Training and Development:
- Conducted extensive training for over 120 employees, including the C-suite, senior leadership, and management teams.
- Focused on operational excellence, JIT production, and continuous improvement techniques.
Tools and Techniques Used:
- Manufacturing Diagnostic®: Assessed the current state of manufacturing processes to identify areas for improvement.
- Strategy Deployment: Ensured alignment across all levels of the organization with strategic goals and initiatives.
- Cell Design: Optimized the layout and operation of manufacturing cells for better efficiency and throughput.
- Line Delivery and Material Presentation: Improved the delivery of production lines and material handling techniques to support JIT production.

Results

Implementation of the VDS Business System® led to a more agile and efficient production system, specifically tailored to handle a diverse product range on a low volume basis.
The training initiatives elevated the skill level across the organization, embedding a culture of continuous improvement and operational excellence.
Achieved significant cost savings of $22 million within the 12-month project period, enhancing overall profitability and operational agility.

Conclusion

This project demonstrates how Value Driven Solutions' expertise in operational excellence and customized production systems can dramatically improve efficiency and reduce costs in the specialized field of medical devices. The proactive training and strategic changes have set the foundation for sustained operational success and continued leadership in the global prosthetic and orthopedic market.