Case Study:
Revolutionizing New Product Development in Furniture Industry
YOU ARE WHERE YOU ARE: Our client, a renowned furniture manufacturer, embarked on an ambitious journey to offer unparalleled customization in their product range, including sofas, love-seats, chairs, and ottomans, with a wide variety of covers and pillows. The challenge was in navigating the complexity of choices and manufacturing constraints, such as cover-frame compatibility and size limitations.
WE MEET YOU WHERE YOU ARE AT: Work Excellence was brought on board to streamline the New Product Development (NPD) process. Our initial assessment focused on understanding the existing product customization options and the manufacturing limitations that impacted product offerings.
PICK A STARTING POINT: We identified the critical need to create a more efficient and responsive NPD process. The first step was to develop a clear visualization of the existing process, pinpointing bottlenecks and areas for improvement.
CONDUCT A WORKSHOP: Through a collaborative workshop, we worked closely with the team to reimagine their NPD process. This involved leveraging an ERP system for better process management and implementing an automated approval system to expedite decision-making.
SOLVE A CHALLENGE
Tangible Outcomes
Streamlined Processes: By implementing stages and gates within the NPD process, we accelerated the development cycle.
Performance Matrix: A product performance matrix was created, providing insights into product performance and guiding future product development strategies.
Efficiency in Customization: We aided in reducing the complexity of customization by standardizing certain aspects, like box sizes and cushion variations, which led to significant reductions in manufacturing time and costs.
Technological Integration: The use of computer systems for running machinery simplified the engineering process, resulting in higher material yield and reduced setup times.
Expand And Scale
The Results:
Cost and Time Savings: The elimination of underperforming product categories saved considerable time, space, and financial resources.
Increased Production Capacity: The restructured NPD process resulted in fewer instances of rework and a higher rate of product development.
This case study demonstrates the power of structured, strategic planning and process optimization in the highly competitive and dynamic furniture industry. By applying the principles of Work Excellence, the client was able to transform its New Product Development process, making it more efficient, responsive, and aligned with market demands and consumer preferences.
