Challenge:
A well-established furniture manufacturer set out to offer extensive product customization—including sofas, chairs, and ottomans with various covers and pillows—but faced complex product combinations and manufacturing constraints. Issues like cover-frame compatibility and size limitations made the New Product Development (NPD) process slow and inefficient, limiting their ability to innovate and respond to market demand.
Approach:
Work Excellence began with a deep assessment of the client’s existing NPD workflow, aiming to:
– Map out the current process structure
-Identify bottlenecks and inefficiencies
-Understand how customization complexity and technical constraints were affecting throughput
This laid the groundwork for reimagining NPD with a focus on speed, standardization, and smart integration.
Solution:
The team collaborated across departments to redesign the NPD process through workshops and digital solutions:
01.
ERP integration to streamline planning and execution.
02.
An automated approval system to reduce delays in decision-making.
03.
Introduction of phased development with gates, accelerating timelines and increasing accountability.
04.
Built a Product Performance Matrix to guide future development based on real results.
05.
Standardized components (like box sizes and cushion options) to maintain variety while reducing complexity.
06.
Integrated technology-driven manufacturing to improve material yield and reduce setup time.
Results: The transformation led to immediate and measurable outcomes:
Reduced time and costs through product line simplification and process efficiency.
The company now responds faster to market demand, without sacrificing customization.
Fewer rework incidents, accelerating the product development cycle.
Higher material yield and streamlined engineering through technology integration.
Improved capacity planning due to better process structure and standardization.
Key Takeaway
This case study highlights the power of strategic process design in the furniture industry. By using the Work Excellence Method to rethink and restructure New Product Development, the company gained speed, scalability, and clarity, transforming complexity into a competitive advantage.