【正文】 ngs for each plant + Package savings for each plant = ($ x 20MM)+($ x 18MM)+($ x 27MM)+($ x 20MM)+($ x 18MM)+($ x 6MM)+($ x 6MM) = $ Rewind savings at each plant Slit savings for each plant Package savings for each plant + + = 29 CU7122997KRA BDP BDP Steps Process Step Key Success Factors Select parable anizations for BDP Disaggregate anizations into major processes Construct firstcut BDP Construct adjusted BDP Quantify impact “ Peel the Onion” in leveraged areas Develop an action plan Implement ?Focus on anizations and processes with the most potential ?Determine drivers of differences at a more disaggregated level 30 CU7122997KRA BDP Priority Matrix Unattainables Back burner High Low Low High Ability to Implement Impact Quick hits Top priority Focus on those areas that will yield the greatest benefits. 31 CU7122997KRA BDP Sticky Tape Top Priorities The top priorities for Sticky Tape are plants A and B and rewinding. ?What do Plants C and D do differently that results in lower costs? ?What drives rewinding costs? Plant D Plant C Plant B Plant A Package Slit Rewind By plant By process $ $ $ $ $ $ Potential Annual Savings ($MM) Potential Total Savings 32 CU7122997KRA BDP Sticky Tape Rewinding Costs *Utilities, occupancy, supplies, supervision O v erh ead *R awm ateri al sLa borPl ant A Pl ant B Pl ant C Pl ant D BD P$0 . 15$0 . 18$0 . 09$0 . 12$0 . 05$0 . 00$0 . 05$0 . 10$0 . 15$0 . 20Rewinding Cost per RollPlant C is the BDP in rewinding labor and rewinding raw materials, plant D in rewinding overhead. Plant D Plant C Plant C 33 CU7122997KRA BDP Sticky Tape Drivers of Rewinding Costs The Bain team determined the drivers of rewinding costs in order to suggest concrete action steps: Run time Master roll load/unload Core load/ unload First quality Defects Ease of moving spools of tape around the room Ease of loading and unloading spools of tape Tape tears Adhesive runs Suggest concrete action steps Labor Raw materials Overhead Rewinding 34 CU7122997KRA BDP BDP Steps Process Step Key Success Factors Select parable anizations for BDP Disaggregate anizations into major processes Construct firstcut BDP Construct adjusted BDP Quantify impact “ Peel the Onion” in leveraged areas Develop an action plan Implement ?Set a BDP target ?Establish a detailed schedule ?Assign responsibilities 35 CU7122997KRA BDP Sticky Tape Action Plan ?Buy larger internal diameter cores to slide more easily into place ?Move rewinding room walls to provide greater clearance for loading/unloading ?Use lower core bins to make core storage easier ?Reduce tension to 122 to reduce tape tears ?Install air conditioning system to reduce adhesive runs Cost $72K $17K $130K + $40K per year Average Savings/ Master Roll $16 $10 $4 $28 $22 Annual Savings $ $ $ $ $ Timing ?Three months to draw down inventory ?Two months for construction ?Now ?Now ?Three months for installation Responsibility ?Purchasing ?Plant manager ?Line supervisor ?Line supervisor ?Technical manager Developing an action plan involved setting targets, establishing a schedule, and assigning responsibilities. 36 CU7122997KRA BDP BDP Steps Process Step Key Success Factors Select parable anizations for BDP Disaggregate anizations into major processes Construct firstcut BDP Construct adjusted BDP Quantify impact “ Peel the Onion” in leveraged areas Develop an action plan Implement ?Obtain mitment at all levels of the anization ?Communicate goals, deadlines and responsibilities ?Celebrate successes along the way 37 CU7122997KRA BDP Sticky Tape Implementation Successful implementation involves obtaining mitment at all levels of the client anization。 municating clearly about goals, deadlines, and responsibilities。 and celebrating achievements made in reaching goals. Commitment Morale boosting ?At senior management level ?At operating management level ?At operating nonmanagement level ?Announcements as milestones are reached ?A running tally of cost savings ?Rewards for superior achievements Communication ?Goals ?Deadlines ?Responsibilities 38 CU7122997KRA BDP Sticky Tape Lessons Learned ?Companies that are BDPs in an aggregate view are not necessarily BDPs in everything ?They can often learn from examining their own operations as well as others’ ?It is necessary to disaggregat