If the saying “You can’t get there until you know where you are going” is true, ZF Industries will definitely reach their goal – with the help of a process improvement “map” known as Value Stream Analysis provided via the Center of Innovation for Manufacturing Excellence (CIME).

Tracy Sykes, Lean Coordinator for ZF Industries, said “the right hand did not know what the left hand was doing,” with respect to the formerly cumbersome internal process involved in the timely tracking and mailing of “charge backs” – a term used when a ZF vendor is charged back for time lost due to a problem caused by the vendor such as a wrong part being sent to ZF.

“Judy Parks and Tim Bala with the Centers of Innovation for Manufacturing Excellence assured us our problem was solvable,” said Sykes. “They introduced me to ‘Value Stream Analysis,’ a process mapping tool as a method for identifying roadblocks.”

By utilizing Value Stream Analysis and working closely with CIME, Tracy and his team were able pinpoint the issues associated with the charge back processing system. “Basically, we had a lot of duplication of efforts; and, people in different areas of our company didn’t have a clear understanding of how their role in charge backs impacted the entire process.”

Once the roadblocks were identified a new method of identifying, recording and delivering charge back data to the vendor was established. “We are now in the training phase,” said Sykes. “Right now, we have implemented about 80% of the new process and are working hard at integrating the remaining 20%. Everyone has a much clearer understanding of the importance of the charge back function and what their function is in the process.”

For more information about Value Stream Analysis, Lean Manufacturing, other process improvement systems or the latest in robotic training, call CIME at 770.531.6350.