22 Pine Street
Bedford, MA 01730
Phone: 781-929-8824

Email:
info@kellehergroup.com
Solutions for your product process:
Fast time to market
Effective stage gates with better decisions
Measurements that drive improvement
Projects on time and within cost targets
Effective global teams
  Consulting Success Stories (PAR) | Skills and Services | Biographies

 


Product
Development
Success Stories

Learn how our
consulting services
have improved the
product development
cycle for companies
around the globe

Contact us to find
out how we can
improve your
product process

 


Our Accomplishments: Problem - Action - Result

Problem: Bottleneck in parts approval process for automotive parts supplier.
Action: Analyzed process with participation of electrical engineering, purchasing and component design and test functions.
Result: Earlier and more disciplined approach to parts approval process reduced conflict between organizations and achieved timely parts approval.

Problem: Machine shop defect rates too high.
Action: Through operator training and six sigma analysis process variance was reduced.
Result: Shop achieved 25 % reduction in discrepancies.

Problem: New Product process cycle time out of control.
Action: Created a standard development process integrating engineering, operations and marketing. Process became basis of management decisions and project reviews.
Result: Project teams able to manage key tasks and cross functional groups delivered input at key points in the process. Results contributed to 55% reduction in cycle time.

Problem: Chinese Consumer Product Company needed basic project management skills.
Action: Developed training course for project leaders which was translated into Mandarin and given to all project leaders and potential project leaders.
Result: All project teams were led by trained project leaders.

Problem: German Auto Parts Company needed improved idea development process to better integrate marketing with engineering and improve the management review process.
Action: A standard was implemented. The criterion for decisions at each major step in the process was documented.
Result: Review process became more effective with a focus of the decisions that needed to be made. Better and faster input decisions were made.

Problem: Consumer Electronics Company needed to improve management of multiple projects.
Action: Developed software tool using MS Project and Excel to summarize key metrics and gain better decisions across multiple projects.
Result: Integrated tracking and management system drove cycle time improvements of greater than 50%.

Problem: Slow response time for equipment design projects.
Action: Developed prioritization process with ranking and simple measurement system balancing tasks and resources.
Result: Process resulted in significant increase in throughput and customer satisfaction.

Problem: Project reviews were not focusing on most troubled projects.
Action: Traffic light system was created to assure critical projects with serious issues were identified early. Teams were coached on decision making orientation for reviews.
Result: Project reviews became more focused on key problems and solutions.

Problem: Final assembly for large capital goods manufacturer taking too long.
Action: Team identified key problem areas and actions required to accelerate test cycle.
Result: Improved training, resolution of incoming quality problems and standard test process yielded 44% reduction in test time.

Problem: Lack of discipline following the process caused many problems in new product development including missed dates and high level of rework.
Action: Developed measurements around process that focused on process drivers.
Result: Reduced cycle time for new product development process by more than 50 % while improving quality of gate reviews.

Problem: Engineering change process between domestic engineering and international manufacturing operation experienced excessive delays.
Action: Analysis of engineering change process and measurements of cycle time pinpointed problem areas.
Result: Process time was reduced by a month through minor process change.

Problem: Excess inventory taking up production and inventory space.
Action: Performed an ABC analysis of the inventory and compared to requirements. Unneeded inventory was removed.
Result: Over time a 50% reduction in inventory was achieved.

Problem: New cross functional team needed coaching to improve effectiveness.
Action: Provided structured process including training, tracking of issues and decisions, and coaching of individual members.
Result: Team effectiveness improved.