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LEAN Workout: BOM Process


In the competitive and rapidly evolving Consumer Packaged Goods (CPG) industry, efficient and effective processes are crucial to maintaining a competitive edge. Our Process Transformation Services specialize in optimizing these critical workflows. In this case study, we'll explore how we helped a client revolutionize their Bill of Materials (BOM) process by leveraging digital technology, resulting in substantial time savings and operational improvements.

LEAN Workout: BOM Process




Process Transformation


Inefficient and Outdated BOM Processes

Our client was struggling with an outdated, labor-intensive BOM process that required employees to print, sign, scan, and either email or fax up to three separate iterations before the paper document was finally filed manually. This cumbersome method left the organization with no means of reporting or tracking the BOM lifecycle, which hindered their ability to make informed business decisions.


Implementing a Digital BOM Workflow

To address this issue, we transformed the client's standard Excel-based form into an intuitive web-based template, streamlining the data capture process and enhancing accuracy. By incorporating an online workflow tool, we eliminated the need for physical signatures and enabled real-time approval tracking. This innovative solution facilitated seamless collaboration, ensuring a smooth and transparent BOM approval process.


Significant Time Savings and Increased Efficiency

By adopting our digital solution, the client experienced a remarkable 95% reduction in their BOM cycle time. We simplified their process by cutting down 12 manual steps to just 3 automated ones: Submit, Notify, and Approve. In addition, our solution allowed the organization to generate insightful reports, empowering them to make data-driven decisions.

Our intervention encouraged widespread adoption of the organization's previously underutilized workflow tool, paving the way for further process improvements across various departments. This success story highlights our expertise in process transformation services and our commitment to delivering meaningful, lasting results to our clients in the CPG industry.

Key Takeaways

  1. Overcoming inefficiencies: By transitioning from a manual, paper-based BOM process to a digital one, we helped the client overcome inefficiencies, significantly reducing the time and effort required to complete the BOM lifecycle.

  2. Simplifying processes: The digital BOM solution cut down the number of manual steps from 12 to 3 automated ones, streamlining operations and enabling seamless collaboration among team members.

  3. Data-driven decision-making: Our digital solution allowed the organization to generate insightful reports, equipping them with the necessary data to make informed decisions and optimize their BOM management.

  4. Increased tool adoption: The successful implementation of the digital BOM workflow led to higher acceptance and adoption of the organization's previously underutilized workflow tool, laying the foundation for future process improvements across various departments.

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