Manufacturing Consulting

Manufacturing Consulting In Focus

Focus on Manufacturing Resource Productivity to Protect Profits
Pharma Manufacturing

Manufacturing |production costs is a hot topic in business today. Prices for raw materials, energy, and water have seen sharp increases.

  • Manufacturing Consulting Overview

    Effective to Optimal
    Innovate Manufacturing to enable business value and agility

    It is generally accepted that manufacturing is a key function which directly impacts a company’s cost position and its ability to meet customers’ demands. Today, businesses are focused on improving manufacturing efficiency because many know their operations are far from optimal. The root cause of this issue is that managers focus specifically on one element of manufacturing rather than the entire operation or organization.

    WGA’s takes a more holistic approach in looking at manufacturing as an integral part of the fabric of the organization in order to:

    • Optimize the shop floor
    • Ensure simple and transparent links between the supply chain and manufacturing
    • Align the entire manufacturing enterprise to enable
      the overall business strategy
    • Reduce the inter-dependencies between manufacturing and product complexity
    • Select the right sourcing for non-core / commodity activities
    • Transform the manufacturing footprint based on clients’ geographical, customer and commercial needs
  • WGA’s Manufacturing Consulting Offerings

    We transform shopfloor efficiency through the use of world-class Lean Six Sigma manufacturing tools and principles. We examine and conduct benchmarking using industry standards based upon WGA’s Recommended Current Practices (RCP) (e.g. maintenance, facilities, cleaning standards, technologies, methods, practices, process), manufacturing costs and productivity profiles to industry competitors.

    Shop floor Improvement

    Indirect Overhead streamlining

    • Lean Six Sigma
    • Cost Improvement Projects
    • Kaizen
    • Competency building
    • Key Performance Indicators (KPI)
    • Visual Factory
    • 5S, 6S and 7S deployment
    • Plant Layout/flow optimization
    • Cell/line process improvement
    • Logistics/inventory optimization
    • Yield/quality improvement
    • Utilization/OEE improvement
    • Process waste and bottleneck elimination
    • Value stream mapping
    • Business process management
    • Industry benchmarking
    • Management Execution Systems
    • Lean Culture Deployment
    • Operational Excellence
    • Workforce right sizing
    • Lean administration and support functions
    • Production planning and scheduling
    • Production engineering/standards
    • Maintenance benchmarking
    • Facilities optimization
    • Warehouse outsourcing/in-sourcing
    • Leadership development
    • Manufacturing Footprint optimization
    • Simplifying Complexity
  • Manufacturing Consulting Case Studies

    Focus on Manufacturing Resource Productivity to Protect Profits

    Manufacturing |production costs is a hot topic in business today. Prices for raw materials, energy, and water have seen sharp increases.

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  • Over the past 10 years, our company has experienced a number of failures and setbacks using each of the “big name” system integrators and consulting companies. We realized that we do a much better job of leading our own SAP efforts and now simply look outside to staff our projects. We always bring in WGA to assist us with all of our project staffing needs. WGA provides us with top talent and high performers that ensure we achieve our goals and projects are on-time and on-budget. WGA’s PMO outsourcing has also allowed us to dramatically reduce our project tracking and management costs. Read more

    AnnSr. Director - Business Systems$38B Aerospace & Defense Contractor

    WGA Consulting has been an outstanding partner for over 10 years on a number of benchmarking, strategy and corporate initiatives. They have helped us with nearly every aspect of our business. I particularly like WGA’s “white glove” style and fact based/pragmatic culture. Read more

    ChrisVice President Operations$34B Industrial Products Manufacturer

    WGA has been instrumental in many of our global initiatives in recent years. WGA has been able to respond and deliver on projects around the globe. WGA’s teams are flexible, easy to work with and always deliver what we need, when we need it. Read more

    KathyGeneral Manager Shared Services Organization$439B Integrated Oil Company

    Our Global Services & Support business unit was working with our internal business partners to develop our 2030 business strategy roadmap. We were having difficulty with prioritizing our business needs. Some of our supply partners needed a firm picture of our roadmap immediately in order to formalize commitments. We reached out to one of our strategic consulting suppliers for assistance, but they wouldn’t be able to dispatch a team to help us for over 3 months. That’s when I called WGA. As a true partner, WGA had their team on the ground 2 days later and we were able to complete our strategy and planning efforts in just 6 weeks! WGA is now our go to/preferred strategy consulting supplier.

    PamelaDirector Business Planning$95B Aerospace and Defense Manufacturer

    WGA Consulting, WGA Advisors, WGA360, Brian and his teams provide exemplary strategy and management consulting services. We have been a reoccurring client for the past 10 years. We turn to WGA when we need fresh ideas and innovation, to resolve big problems and when we need to successfully complete initiatives. Don’t use McKinsey, BCG, Bain, etc, call on WGA instead. Read more

    MichaelVice President Operations$49B Global Oil & Gas Company

    After two decades of organic growth, many of our managers in the organization were starting to see a chronic problem. Our operations had become too complex to manage. Our executive leadership agreed and my department was assigned to lead the effort. We reached out to WGA to help us identify and prioritize meaningful simplification opportunities. They worked with us to facilitate designing, planning and implementing all aspects of the program. The results were incredible, we consolidated and reduced over 950+ global positions and eliminated over 7000+ waste and bottleneck problems. We also consolidated and relocated three of our manufacturing centers into one lower cost location. The bottom line results of WGA’s services were outstanding! Read more

    ZachVice President Organizational Effectiveness$87B Aerospace and Defense Contractor

    Our network of Automobile accessory plants were experiencing unexpected levels of demand from our major Automotive customers. Our operating costs were out of control, and we were missing delivery dates. Two of our largest customers threated to cancel over $500M dollars in annual contracts. After reaching out to several tier-1 management consulting firms, we selected WGA Consulting based upon their unique, innovative and accelerated approach. In just 2 weeks, WGA had identified a combination of people, culture, process and operating problems, prioritized action plans and temporarily took over executive leader roles at our plants to drive the improvements. In less than 3 months, WGA had resolved our issues and brought our operating costs down by over 32% ($127M/annually) and improved our customer OTIF by 29% to 98.9%/week. WGA is our trusted/go to consulting partner when we need help! Read more

    EllynVice President Manufacturing Operations$19B Global Automobile Accessory Manufacturer

    WGA helped us design, develop and deploy improvements in our global procurement organization. WGA’s category management strategy enabled us to realign our regional procurement centers to focus on maximizing the value of our resources, improving customer service levels with our internal business customers and consolidating overlapping positions across the enterprise. During our second year of the category management structure we have realized over $90M in operational cost reduction and increased all of our internal metrics for speed, quality and customer service. Read more

    JamesDirector Global Procurement$220B Integrated Oil and Energy Company

    3 Years after purchasing two smaller competitors in our industry, our executive leadership team was struggling to see the cost savings of our consolidation efforts. Two other strategy consulting firms were brought in to assist us in determining and fixing the problems. After we spent $18M USD in 6 months with limited success, we decided to end the contracts early with the two other firms. Our COO recommended that we call WGA. In just 3 months, WGA had developed a strategy to simplify our operational processes, merge overlapping business systems and consolidate our service offerings in various international operations. Since our first project, WGA remains our key trusted strategy and consulting partner for all of our business needs Read more

    JavierSenior Vice President Corporate Strategy and Planning$44B Aerospace and Defense Contractor

    After our Telematics project missed key milestone dates and our company was running national commercials that the new technology would be in our cars in 6 months, we called WGA to help. WGA conducted a healthcheck of our Telematics PMO and provided us with a turnaround strategy and plan. We were initially shocked by the problems WGA identified and had to take some personnel actions to achieve our deadlines. WGA’s turnaround strategy was simple to execute and allowed us to deliver our Telematics project 1 month earlier than planned. WGA’s ability to get to the root-cause and their comfort with delivering bad news to our executive leadership reflects their reputation for integrity and professionalism. Read more

    GeorgeChief Information Officer$89B Automobile Manufacturer

    We worked with WGA to fine tune our long term business strategy to address unforeseen changes in Asia, Canada and South America. WGA’s independent analysis of additional plausible scenarios helped us realign the timing of our capital investments and adjust our organizational redesign. WGA’s foresight and deep cross-industry experience has helped us on a number of occasions advert unnecessary challenges. Read more

    MikeExecutive Vice President Corporate Planning and Strategy$68B Industrial Manufacturer

    After making over 400 safety related improvements in our global operations, we determined that many of our leaders weren’t convinced about the urgency of these changes. WGA put together a culture change strategy to immediately achieve adoption. WGA helped us deploy a number of initiatives, including a leadership training and coaching/mentoring program along with improvements to our global leadership competency framework. WGA was essential in helping our organization make these changes stick. Read more

    BobSenior Vice President Shared Services Organization$76B Global Oil & Gas Company
    Strategy Consulting

    After failed attempts by two other big name consulting firms, I was under pressure from our executive leadership to make our supply chain optimization happen. We needed assistance from a firm that had global reach, could deploy immediately and were experts at identifying improvements and executing changes. I called on WGA to help us turnaround our efforts. WGA delivered on their commitment and helped us realize an additional ($57M/yr) in cost reductions. WGA is excellent to work with and delivers high impact results! Read more

    WilliamVice President Supply Chain Operations$178B Global Automobile Manufacturer
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