How Apex Manufacturing Transformed with the 7+ Index
📌 Industry & Business Type: Manufacturing | Large Enterprise
The Challenge: Increasing Production Efficiency & Reducing Costs
Apex Manufacturing, a global producer of industrial components, was facing significant operational inefficiencies, rising production costs, and supply chain disruptions. The company was struggling to meet growing customer demandswhile maintaining quality and profitability.
Key challenges included:
-
❌ Production inefficiencies – Outdated manufacturing processes leading to high waste and downtime.
-
❌ Rising operational costs – Increased raw material expenses and inefficient resource allocation.
-
❌ Workforce disengagement – Low morale among factory employees due to lack of process improvements.
-
❌ Supply chain bottlenecks – Delays in raw material sourcing and delivery.
-
❌ Lack of digital transformation – Reliance on manual reporting systems instead of automation.
Apex Manufacturing needed a structured transformation strategy to optimize manufacturing processes, improve cost efficiency, and increase overall production capacity.
Our Approach: Implementing the 7+ Index & Change Management Strategy
Kara introduced 7+ Index, applying the 7 Steps to Profit methodology to assess Apex Manufacturing’s leadership structure, operational efficiency, and workforce engagement.
Step 1: Brand DNA – Defining a Clear Vision for Operational Excellence
📌 Conducted leadership alignment workshops to unify decision-making across manufacturing and logistics teams.
📌 Developed a North Star strategy to guide long-term efficiency improvements.
📌 Result: Stronger executive leadership focus on lean manufacturing principles.
Step 2: Culture – Creating a High-Performance Manufacturing Workforce
📌 Implemented employee engagement programs to improve morale and retention.
📌 Developed collaborative training initiatives between production and quality assurance teams.
📌 Result: 25% increase in employee satisfaction and productivity.
Step 3: Strategy – Optimizing the Manufacturing Business Model
📌 Designed a three-year operational roadmap focused on efficiency and automation.
📌 Integrated real-time performance tracking using 7+ Index scoring.
📌 Result: 18% improvement in factory output efficiency.
Step 4: People – Upskilling & Workforce Development
📌 Introduced lean manufacturing workshops for plant supervisors.
📌 Designed automated workflow training programs to improve digital adoption.
📌 Result: 30% increase in production team efficiency.
Step 5: Customer – Enhancing Order Fulfillment & Supply Chain Speed
📌 Improved inventory forecasting models to prevent supply chain disruptions.
📌 Introduced AI-driven logistics tracking for faster order fulfillment.
📌 Result: 20% reduction in order processing time and improved customer satisfaction.
Step 6: Proposition – Building a Resilient & Scalable Manufacturing Process
📌 Implemented predictive maintenance systems to prevent machine downtime.
📌 Developed energy-efficient production workflows to meet sustainability targets.
📌 Result: 15% decrease in operational waste and energy costs.
Step 7: Execution – Implementing Change & Measuring Impact
📌 Installed real-time manufacturing dashboards to track KPIs and progress.
📌 Developed a continuous improvement framework based on 7+ Index insights.
📌 Result: 22% increase in overall plant efficiency and cost savings.
The Results: Manufacturing Excellence & Cost Reduction
By implementing the 7+ Index methodology, Apex Manufacturing achieved:
📈 £65 million in cost savings through automation and lean workflows.
📈 30% reduction in production downtime, leading to faster output.
📈 20% improvement in supply chain efficiency, reducing delays and backorders.
📈 Sustainability improvements, lowering waste production by 18%.
Call-to-Action: Want Similar Results for Your Business?
Are you ready to implement a structured change management approach?
📍 Book a Consultation to discover how 7+ Index can drive profit growth in your organisation.
Trusted by
