Overview

Discrete manufacturing is built on the orchestration of thousands of moving parts : machines, materials, people, suppliers, BOM accuracy, changeovers, and takt‑time discipline. When any element slips, the entire value stream destabilizes. The result is schedule slippage, overtime burn, expediting costs, high WIP, excessive inventory, bottlenecks, poor OEE, quality escapes, and chronic firefighting.

Across automotive, machinery, electronics, apparel, and furniture, plants face the same operational realities:

• Flow instability from bottlenecks, changeovers, and unbalanced lines
• Demand‑supply mismatch caused by weak S&OP and inaccurate forecast leads to MRP chaos
• Equipment reliability issues reducing availability and throughput
• Engineering changes triggering rework, obsolescence, and confusion
• Supplier unreliability causing last‑minute shortages and costly expediting
• Quality problems inflating scrap, rework, and warranty risk

AEM Consultancy (Analyze . Eliminate . Maximize) helps manufacturers build stable, predictable, high‑performance production systems through AEM’s Analyze . Eliminate . Maximize approach which include Lean Six Sigma, data sciene and ML Strategies. By aligning planning with capacity, eliminating root causes of variability, and maximizing flow with digital and lean tools, we transform unreliable plants into consistent, high‑throughput operations.

Our approach focuses on the levers that drive manufacturing excellence:

• Throughput & OEE : Stable flow, fewer stoppages, higher availability
• Cycle time & changeover reduction : Faster switching, lower WIP
• Better schedule adherence : Fewer misses, better customer reliability
• Inventory health : More turns, fewer stock‑outs of A‑items
• Quality improvement : Causing last‑minute shortages and costly expediting
• Supplier performance : Stronger OTIF, less expediting
• Cost to serve : Lower overtime, freight, and unit cost