The situation
Neither the supply chain director nor the manufacturing director could see the pattern from their own seat.
Plant Manager scope: x-ray lines, digital detectors, NDT and pooled-asset refurbishment in an FDA-regulated, ISO 13485 environment. Material outages were paralyzing production. Directed elsewhere for months; root cause identified in 20 minutes once the right data sets were overlaid.
20 min
To root cause, once the data sets were overlaid
The outcome
90%
Material outage reduction
72%
Monthly output increase
How it happened
- Cross-domain overlay of workforce hire dates against parts outages surfaced the root cause
- No field supply chain experience in the role; institutional vendor knowledge had no foundation to build on
- Legacy SAP recovery rebuilt procurement discipline; cross-training reduced single-point dependencies
- Process flow and scheduling optimization in the test labs improved throughput and delivery reliability
- 71% OTD improvement and 30% reduction in escaping defects, sustained through a CEO-change restructuring
- Cross-domain data overlay
- SAP recovery
- Cross-training
- Scheduling