Cost Deployment in Action – Structuring Losses under WCM

Client
Getrag Group, China
Date
March 15, 2019
Services
Cost Deployment | Sustainability & Resilience
Website

Major Improvments

  • Full Loss Tree Mapping
    Structured all losses into categories (Productivity, Quality, Energy, Logistics), creating a full WCM-aligned cost tree.
  • Data-Driven Prioritization
    Used historical cost records and actual incidents to rank top contributors to total cost per unit.
  • Cross-Functional Deep Dive
    Engaged production, finance, quality, and logistics teams in a joint analysis of root causes behind critical losses.
  • Deployment Board Setup
    Built a visual board system to track top 20 cost drivers and link to targeted improvement projects.

Application Scope

  • Machining Cell – Quality Loss Focus
    Identified most frequent scrap causes and quantified financial impact using cost-per-defect indicators.
  • Assembly Line – Time Loss Analysis
    Uncovered setup time waste and idle machine intervals, assigning monetary loss to each source.
  • Energy Cost Deployment
    Deployed energy monitoring per station and linked excessive use to specific shift/time blocks.
  • Lean Budget Integration
    Connected cost deployment results with the site’s lean annual budget and kaizen prioritization plan.

Customer Says

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