Our client was a Europe-based company developing and manufacturing key electronic components for customers in the consumer electronics; based mainly in Asia.
They were in the ramp-up phase of a new product, and growth was explosive. However, they were suddenly confronted with catastrophic product failure affecting 40% – 60% of the production output.
APPROACH
With senior management we worked on strategic and operational alignment with global market conditions. Together with cross-functional / level teams, we set an aggressive 23-week action plan for bringing production under control.
In production, we focussed on solving the quality problems, increasing the availability of production equipment and improving delivery reliability.
Through collaboration and knowledge transfer, we ensured that employees were empowered and accountable for the delivery of their improvement areas. We helped them to apply the relevant tools they had been trained apply in a skilled manner.
Together with the teams we introduced a new Performance Management System to support their new ways of working. By involving employees in the design, they developed a strong co-ownership of the changes, their unit and its results.
Inevitably, after every recession the economy grows again. Research by Bain & Company, Harvard Business Review, Deloitte, and McKinsey shows that the best companies continue to grow their EBIT during a recession and also accelerate faster after it when compared to other companies (see Figure 1). Let’s take a look at what the winners do differently to accelerate their profitability during and after a recession.
Figure 1. “Winning companies accelerated profitability during and after the recession, while losers stalled” (Source: Bain & Company).
7 KEY ACTIONS TO ACCELERATE YOUR PROFITABILITY DURING AND AFTER A RECESSION
We’ve integrated this research material to generate a clear picture of the 7 key actions you need to take for success.
1. CREATE CLARITY OF DIRECTION AND ORGANISATIONAL ALIGNMENT
How do you want your company to look and run in three to five years from now? And in one year? What are the vital few strategic initiatives to focus on? Make sure your leadership team is committed and fully aligned.
2. UNDERSTAND YOUR STRATEGIC AND FINANCIAL POSITION
Mapping out your plans depends on your strategic and financial position
(see Figure 2).
Figure 2. Mapping out your plans requires an assessment of your company’s strategic and financial position (Source: Bain & Company).
3. FREE UP “CURRENCY”
This is not about blunt cost cutting; the focus is on aligning your spending with your vision and strategic initiatives. Zero-based Alignment / Budgeting is a good way to select and make lean those activities that are fully aligned. The “currency” you free up can strengthen your balance sheet and support your investment agenda.
4. RETAIN YOUR CUSTOMERS
Retaining your customers is so much cheaper than acquiring new ones. The margin impact is significant. Explore ways to help your customers through the downturn and strengthen your relation with them. And be sure to focus on the right customers.
5. PLAN FOR VARIOUS SCENARIOS
Nobody knows when and how a downturn will unfold and when the economy will start to grow again. The winners have developed various scenarios, and they know how they should act in each scenario. This allows them to move quickly and decisively.
6. ACT QUICKLY AND DECISIVELY
Winning companies act quickly and decisively, both in the downturn and particularly in the early upturn when the opportunities start to arise. They have already created the “currency” to invest.
Not all companies have been equally aggressive in adopting new technologies. There are many opportunities here for improving efficiency or generating more value and thereby gaining a competitive advantage. The current COVID19 pandemic could well be an important catalyst.
This means that you have to be prepared for an economic downturn to come out as one of the winners. It should be noted that in these key actions, there is, in fact, no difference between being prepared for an economic downturn and running a business for continuous and maximum success. This picture is consistent with one that emerges from one of our other articles “How to create value in Industrials?”.
CHALLENGE
A chemicals company wanted to increase production capacity and reduce costs in sites across Europe. The company was struggling due to a prolonged downturn in the market. Profit margins were all but gone and they wanted to take the opportunity drive down the cost breakeven point, make a step change in operational performance and prepare for the next upturn of the market.
APPROACH
Conducted a detailed four-week Analysis & Design at one site to fully understand the issues and identify the improvement potential.
After 6 weeks of Implementation, we conducted Quick Scans at the other sites to check local improvement potential. After 4 months, we started a European rollout that was completed within 24 months and addressed all 8 sites: we simplified ways of working, implemented aligned operating models, drove up the OEE and eliminated fixed costs. Whilst still working on this assignment we identified major improvement opportunities in new product development and introduced a product innovation improvement programme.
Many companies need to work hard to protect their bottom line. Driving down costs is a sine qua non – but done wrongly, it will damage the business. At the same time, growth drivers need funding to provide the means for future growth. Smart cost cutting will prune a company back to health and free up the cash to provide oxygen for growth drivers. Let’s explore how this is done.
Be explicit about value delivery
Be clear on the value to be delivered to your stakeholders both now and in the future. Design a strategy that enables resilience, irrespective of economic conditions. What products and services should you deliver? Work out an appealing vision that is also explicit about the mindset and behaviours that will create its success – this is a crucial factor that is all too often overlooked.
Align cost structure with vision
Once you have formulated your new vision, you will need to map out and understand the current activities and cost structures in detail. Work with five main questions: What activities can you not live without? What activities can you stop? What activities can you simplify or aggregate? Where can you redefine demand for activities? What new activities do you need?
Be clear on the must-haves and eliminate unnecessary or nice-¬to-¬have services and activities. Decide what can be outsourced, offshored or insourced, and how procurement can be rationalised.
Align and digitise the operating model
Design lean end-to-end processes
Answers to the questions listed above are the input for an iterative process that starts with the redesign of end-to-end business processes. Process mining is a tool that provides great insights into your current processes and will help you decide what to keep and what to adapt.
Drive down organisational complexity
Using the redesigned processes, assign responsibilities and accountabilities as low as possible in the organisation. Design logical, complete functions and think process flow, not department. Automate activities through software robots and integrate them as virtual employees with roles, accountabilities and reporting lines in the organisation. Create additional organisational layers only if they add value.
Create an effective reporting and meeting structure
Reduce the number of meetings held. Keep them focused and as short as possible. To improve a meeting’s effectiveness, be clear on what the meeting is for, who has to attend (and who not) and what information needs to be made available for the meeting. Each attendee should have the information that is required to do a good job – no more and no less.
Digitise
Capitalise to the max on the opportunities that intelligent automation provides and optimise the technology landscape. This drives down cost and improves both quality and speed.
Implement decisively
Design a roadmap from the current state to the future state and act decisively. Identify activities, but focus on results. If the activities don’t deliver the planned results, adapt the activities, not the timing of results delivery. Reinforce and develop the employees in their organisational roles – align their accountabilities and the implementation deliverables. The way the implementation is done shapes the mindset and behaviours in the organisation. Be sure this is in line with how the vision is formulated.
Maintain a relentless focus on cash and margin
Identify and deliver immediate operational cost measures to start generating cash. Move continuously from quick wins to more complex opportunities. Stabilise the supply chain, optimise working capital and optimise the supply chain processes. Keep on driving operational efficiency. Address the top line: address product and service offerings in line with your strategy and optimise pricing. Maintain a relentless focus on cash and margin throughout.
Provide oxygen for your growth drivers
Ensure that the growth drivers are well-positioned on the management agenda and the required resources are assigned and protected. Keep on driving their growth towards stretching KPI targets.
CHALLENGE
A global manufacturer of engineering plastics was struggling to improve safety performance at its largest site.
APPROACH
Six-week Analysis & Design to understand the requirements, get a good insight into the blockages of moving forward and to co-create an approach for the Implementation.
During the eight-month Implementation we created the space and conditions for change, removed blockages (mainly top team behaviour), reconnected the various organisational layers, simplified the HSE processes and system, and conducted on-the-job coaching built upon brain-based safety principles.
CHALLENGE
An engineered capital goods company was struggling with ever-changing priorities and was slow to innovate.
APPROACH
Together with the top team we conducted two short workshops on vision and strategic goals, identified the KPIs and set the targets.
We then aligned the organisation vertically and horizontally through a strategy deployment process down to the shopfloor. KPIs and targets were integrated in the management system to ensure actual delivery.
CHALLENGE
A high-tech industrial equipment manufacturer has a complex supply chain with many SKUs and long lead times. It was struggling to match supply with demand, which was fluctuating strongly. Multiple engineering changes.
APPROACH
Through data analytics we mapped the characteristics of the business and identified key levers for improvement. This led to the design and implementation of a dedicated S&OP application – a decision-support tool.
CHALLENGE
A high-tech and consumer electronics company wanted to train and coach green belts and black belts in Lean Six Sigma.
APPROACH
Carry out in-house training with focus on personal and value-add projects of the participants.
Coach the participants over a longer period to make sure knowledge is transferred into changed behaviour.
Coach black belts to become master black belts and thus anchor Lean Six Sigma in the organisation.
CHALLENGE
A high-tech and consumer electronics company wanted to train and coach engineers and developers in Design for Six Sigma.
APPROACH
Carry out in-house training with focus on personal and value- add projects of the participants.
Coach the participants over a longer period to make sure knowledge is transferred into changed behaviour.
Coach the engineers and developers and thus anchor Design for Six Sigma in the organisation
CHALLENGE
Global chemical compounds company with multiple factories with multiple production lines.
Medium term decisions on allocation of products to product lines.
Strong influence of batch size and product sequence on output of production lines.
Need to plan allocation of products to production lines at least one year up front.
Uncertain demand and strong influence of market fluctuations.
Complex global supply chain cost and turnover picture including tax regimes.
APPROACH
Build a mathematical optimisation model of the global supply chain.
Embed the model in a user-friendly software system to support decision making.
Involve future users and management to guarantee quality and acceptance of decision support system.
Transfer system to the organisation and remain available for support.