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ANGI Energy Systems
Cutting lead times and labor costs
Faced with extreme surges in demand, ANGI Energy Systems needed to improve its workflows and shorten production timelines. Wipfli helped the manufacturer find critical process improvements and substantial time and cost savings.
The Challenge
At ANGI Energy Systems (ANGI), sales for a top-selling product were projected to double. To capitalize on the market momentum, the manufacturer needed to significantly cut its production cycle and delivery timelines.
The Solution
Wipfli and ANGI assembled a core team to evaluate critical manufacturing processes and potential solutions. They videotaped processes to analyze how information, products, materials and people interacted and encouraged creative solutions to remove roadblocks. After a discovery phase, ANGI selected high-impact projects to implement, and Wipfli helped it pursue targeted improvements. Leveraging business intelligence and exception reports, ANGI re-sequenced steps in final assembly and redesigned workstations and the physical environment to support the new workflow.
The results
ANGI reduced its labor content from 220 hours to 110 hours in an ideal state, and consistently sustained 150 hours (a 31% reduction). ANGI also cut lead times from 10 days down to three. The manufacturer also realized substantial labor cost savings, gained production capacity and established more predictability and “standardization” in its work. Now, ANGI is ready for long-term market growth.
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decrease in lead times
