Context
A German electronics manufacturer had set up assembly operations in Ho Chi Minh City but was struggling with high defect rates, excess inventory, and missed delivery targets—threatening key customer relationships.
Our Mission
Diagnose root causes, design an improvement roadmap, and implement lean manufacturing principles to achieve 20%+ productivity gains within 9 months.
Our Approach
Our team spent 3 weeks on-site mapping the value stream and identifying 14 major waste sources. We redesigned the line layout, introduced Kanban replenishment, and deployed digital SPC monitoring. A structured Kaizen program engaged all 180 operators in continuous improvement.
Before & After Results
| Metric | Before | After |
|---|---|---|
| OEE (Overall Equipment Effectiveness) | 58% | 74% |
| Defect Rate (ppm) | 4,200 | 890 |
| WIP Inventory (days) | 11 days | 4 days |
| On-Time Delivery | 71% | 96% |
"The MAXAM team integrated seamlessly with our Vietnamese workforce. The results speak for themselves—our Vietnam plant is now a benchmark for our entire group."
Klaus Steinberg
Director of Global Manufacturing — PrecisElektronik GmbH