The resultant simplified end-to-end processes reduced the planned implementation costs by 18% (fewer processes and process steps to be implemented)




The Client's Challenge

The client had just completed a nine-months exercise with PWC to rationalize and improve its processes prior to installing selected software. However, we demonstrated that we could further simplify the (improved) processes when we took a 21-step ‘improved’ process and reduced it down to 5 steps.

We were asked to help the team quickly simplify all of the processes before systems design and implementation planning commenced.


The areas that Olex Cables simplified included:

  • Enquiries/quotes/tenders
  • Sales order processing
  • Production planning
  • Manufacturing control
  • Inventory management
  • Cash collection
  • Order dispatch/Distribution
  • Complaints management
  • Expenses/payments.

This represented nine concurrent process streams


Due to time constraints, the process was run intensively over six weeks across all of the processes with a full-time team of 16 Olex staff

All Olex sites in Australia and New Zealand were covered

We assigned 2 consultants to lead the assignment

The team that had completed the nine-months re-engineering study was successfully convinced to now do it again, faster and to question their previous results.

The Results

  • The identification of a common “Vision” for the project highlighted previously unknown misunderstandings as to the business goals to be achieved and the meaning of ‘success’

  • The number of processes were reduced by 46% and the number of process steps overall was reduced by 38% (from the already ‘improved’ processes)

  • The principles underlying the manufacturing planning process were revised to make them customer-driven

  • Manufacturing/purchasing flexibility was increased through common process design

  • Issues with the already purchased solution software were identified (well before implementation) allowing work-arounds to be designed and optimized as part of the project

  • Sixteen Olex staff were educated, coached and trained in Business Simplification techniques.

The Payoff

Concepts such as cross-docking, account management and proactive credit management were introduced and adopted

The resultant process and information flows were used to evaluate, at a detail level, the software products already purchased and highlighted gaps and deficiencies for remedial action

Problems previously unresolved (sometimes never even raised) were identified, addressed and resolved.

Explore Business Simplification Further

Read "TOP Thinking" blog posts on Business Simplification by clicking here.

And read "TOP Thought Leaders" by clicking here.

Topics: Project Success, Business Simplification, Manufacturing, Olex Cables