Pull Flow Adoption to Streamline Production and Reduce Work in Progress

Context

Specialized in manufacturing electrical cables coated with high-performance materials such as silicone or PTFE, our customer historically relied on a push flow production model, based on make-to-stock manufacturing. In a drive for continuous improvement and increased competitiveness, they initiated a strategic shift toward pull flow production, i.e., make-to-order. This change aimed to reduce WIP, streamline flows, and enhance the organization’s agility. Internal efforts had been initiated, but were interrupted following the departure of the project manager. Lacking the resources to relaunch and manage the project, the company turned to Merkur to take over and drive the transformation forward.

Problem

Facing the need to transform its production model to reduce WIP, improve responsiveness, and streamline flows, the company quickly encountered a lack of resources and tools to effectively manage this transition. Without a dedicated project lead or reliable indicators to track actions, implemented initiatives progressed slowly. Coordination between planning and shop floor teams weakened, compromising the overall impact of the action plan. In this context, the intervention of an external partner with leadership, methodology, and the right tools became essential to reignite the project and ensure its success.

Need

Field support to structure the improvement plan and develop key tools. To effectively restart its operational transformation plan, the company needed structured support, combining strategic vision and concrete field actions. Merkur stepped in with a human and methodical approach : action plan facilitation, team coordination, and implementation of tools to improve productivity monitoring and strengthen production planning. This support helped reestablish team momentum and lay the foundation for a smoother, more responsive, and sustainable management system.