Setting up a factory from scratch requires foresight and planning to effectively lay the foundation for the future. The greatest opportunities for long-term cost-savings come from optimizing efficiency, productivity, and safety from the very beginning of its operations.

• Establishing new factories: The project is managed in several steps starting with site selection. We take into account every part of your production process to determine the best equipment and design for your needs with the goal of reducing overall risk and saving costs in the future.

Our experts can quickly troubleshoot problems and determine the best next steps to make the factory operation as smooth as possible, followed by the factory launch. 

• Factory compliance with controls and standards: Factories should have management systems in place to ensure continued compliance to various legal, regulatory, technical and corporate governance requirements. These requirements are designed to protect both the business and customers from risk, so that they can legally and efficiently meet the right quality to manufacture and sell their products.

• Factory Equipment Maintenance: Most manufacturers believe that purchasing complex machinery and equipment will address the problem of high labor costs, however, we have seen multiple cases of a factory purchasing complex equipment and not being able to maintain it properly. A small piece of complex equipment can put a plant out of business through a combination of downtime and poor product quality.
• Enterprise Resource Planning (ERP) Consulting: An appropriate ERP for your operations will give you visibility into purchasing, warehouse, and production, among others. And it will reduce a lot of manual work in your factory. We can support, from the users’ perspective, the implementation of a complex ERP (e.g. SAP, Oracle) as well as much more simple ERPs. Different types of ERPs are appropriate for different businesses, so in our ERP consulting service we can also recommend which solution is best for you.
• Supply Chain Management: Did you know that, in a typical factory, inventory costs about 25% of its total value to the company every year? And would you agree that poor production planning is one of the biggest enemies of productivity?

So we offer you clear solutions to overcome this:

• • Production planning: A good planning system allows the factory to pull the components, materials, and people that are needed at the right pace to meet the demand from customers in the most cost-effective manner. It means your factory performance, productivity and utilization are high and your on-time delivery is good.

• Procurement: It is critical that procurement staff support the production plan. Our consultants often see large batches procured many months in advance, with the objective of getting a discount from the supplier.

This practice ignores many of the hidden costs of excess. 

• Warehouse management: Inventory control is a key activity in the fight against aged inventory that might turn into scrap. Simple metrics can help warehouse staff, purchasers, and planners keep inventory levels low.

• Industrial Opportunity Identification: 

Today’s industrial businesses are facing an ever more complex environment characterized by oversupply and a variety of information flows that constantly evolve.

Products/services are becoming more diverse and adaptable, customers require individualized solutions and personalized customizations, while product and service life cycles are shortening. The resulting challenge for businesses and business executives is how to extract valuable business opportunities and turn them into viable business ventures. 

• Products and Technologies Assessment:

Evaluate the resources and capabilities the company has and needs to develop, and/or need to acquire to deliver the innovation portfolio and pipeline.

• New Product Introduction (NPI): Are you planning to launch production of a customized product in your factory? There are many ways this project can get derailed, resulting in long delays and significant cost overruns; So here we provide solutions And the correct treatments, by following steps: 

• Supplier selection: In case you are working in a new company and starting to manufacture, the company has to focus on the importance of suppliers and sub-suppliers. They are probably the main cause of new product introduction delays.

• Line arrangement: Let’s say you have selected a main supplier that will take care of some fabrication/machining as well as assembly and testing. The question here comes, Have they set up their processes in a way that will make it easy to reach your quantity and quality requirements? Maybe they have not dedicated some area to your new products -in that case, will this cause issues? We can assess their line setup and provide suggestions for improvement.

• Employee Training: If your product is different from It is usually made by the factory, or you have introduced new machines and processes The people working on your product need some training, Our company is the best partner for preparing and evaluating employees professionally.
• Testing the processes: Making a few pre-production samples does not uncover all the issues that you may face once mass production is launched. One of the steps of the PPAP (“Production Part Approval Process”) is to force the line to “run at rate” for a certain time. 
• First Article Inspections (FAI):  Some customers require by contract to do FAI for the new products that have been discontinued for a while, especially when there are significant changes in process, equipment or manufacturing personnel. Our engineers can help you to implement the FAI right procedure. 
• The real beginning: The previous steps were done right, and FAI steps take place at the expected timing and No major issues emerged. It means that following the process we outlined above is the best way to get your new product made and launched with favourable results.

• Factory Transformation:  Is your factory unable to make enough good parts to meet your customers’ demands, and does it have major problems? This is the most common reason why a factory transformation becomes a must. We have been involved in a number of similar situations and we usually need to follow a three steps approach.

• Getting production back on track: One thing that cannot be waited for is an increase in the number of high-quality products. At Ejaad, we study the situation first and determine the main cause of the problems, for example, a weak process control system or poor maintenance, insufficient equipment and forces, etc., through:
• Getting quality and capacity up to standards: Once production is back on track, other fundamental gaps need to be addressed, usually working on quality improvements and a process improvement plan. Quality and capacity also depend greatly on what the component suppliers are delivering. We often see severe quality issues coming from suppliers, as well as inappropriate supplier management on the part of the purchasing department.
• Fighting margin erosion over time: Once the pressing issues have been addressed, it is time to ensure the factory is well organized and positioned for profitable growth in the future. 

•  Process Improvement: We work on solutions that make sense to your business. For example, if the changeovers in the production line are an obstacle to the good flow of materials, we help re-engineer them based on the SMED approach. 

• Staff Involvement: Involving your employees in introductory training modules on applying improvement tools and techniques can help you leverage their ideas and, in turn, help you save a lot of money.
• Factory performance reporting: To find out whether the factory operates efficiently and effectively or not, it is necessary to build reports and performance indicators that reflect the performance of the factory, such as efficiency, productivity, and utilization. Based on these reports, it is possible to know the deficiencies and determine the starting point and then the goals that the facility seeks to improve the factory’s performance.

• Quality improvement: 

• • Statistical process control: We help factories identify the process control parameters that are critical in their operations, we collect data and consult suppliers in order to decide on these parameters’ acceptable levels.

• Mistake proofing manual operations (“poka yoke”): It makes sense to focus on the sources of mistakes that have the highest impact on the finished product’s quality. This is typically the industrial engineers’ and the process engineers’ job. Unfortunately, most operators in factories consider human mistakes unavoidable. This is the wrong attitude!. 

• Quality system: A good quality system also ensures feedback from customers is well correlated with the issues detected by internal inspections and internal audits. If you are regularly surprised by customer complaints, your system is not set up properly. 

• Supplier quality: Your suppliers have a direct impact on your own products’ quality. As our consultants often say: “Your suppliers’ quality is your quality.” Yet this is often neglected by manufacturers. We often see failure rates to the tune of 20% on some incoming QC reports, and yet most of these batches are released to production.
• Product design: One source of quality problems might be the product design. It might not be conducive to good manufacturability, and in turn that might affect quality. In some cases, we can work with the production and the design departments to make changes without losing the original design and engineering intents of the design.