From silos to clarity
Research
2019-2020
Research
Infographics and data visualization
Report
Swegon North America, a market leader in sustainable indoor environment solutions, faced challenges due to communication gaps in its engineering change management process, resulting in inefficiencies and unnecessary costs. As part of my LEAN Six Sigma Green Belt program, I led a research project to identify friction points and provide actionable solutions to improve their operations.
1 — Background
In manufacturing, a single change request, such as a product change after production has begun, can trigger a chain of challenges across engineering, operations, and the supply chain. An Engineering Change Order (ECO) is essential for managing these changes. Without transparent and timely communication, the process creates silos, which negatively impact business outcomes.
1 — Background
In manufacturing, a single change request, such as a product change after production has begun, can trigger a chain of challenges across engineering, operations, and the supply chain. An Engineering Change Order (ECO) is essential for managing these changes. Without transparent and timely communication, the process creates silos, which negatively impact business outcomes.
1 — Background
In manufacturing, a single change request, such as a product change after production has begun, can trigger a chain of challenges across engineering, operations, and the supply chain. An Engineering Change Order (ECO) is essential for managing these changes. Without transparent and timely communication, the process creates silos, which negatively impact business outcomes.
2 — Approach
I created a clear business case and research plan, outlining the challenges, required resources, and key stakeholders, ensuring alignment with leadership. My approach combined research, cross-functional collaboration, and process mapping to uncover communication breakdowns, visualize workflows, and co-create solutions with the teams impacted by these inefficiencies.
2 — Approach
I created a clear business case and research plan, outlining the challenges, required resources, and key stakeholders, ensuring alignment with leadership. My approach combined research, cross-functional collaboration, and process mapping to uncover communication breakdowns, visualize workflows, and co-create solutions with the teams impacted by these inefficiencies.
2 — Approach
I created a clear business case and research plan, outlining the challenges, required resources, and key stakeholders, ensuring alignment with leadership. My approach combined research, cross-functional collaboration, and process mapping to uncover communication breakdowns, visualize workflows, and co-create solutions with the teams impacted by these inefficiencies.
3 — Key insights
Understanding the process: I conducted an in-depth study of Engineering Change Orders (ECOs), which serve as the backbone for documenting and managing changes to product components, Bill of Materials (BOM), and customer requirements.
Bridging gaps across teams: I led workshops with Project Management, Engineering, and Operations to identify how siloed communication and unclear responsibilities were impacting timelines, costs, and quality.
Mapping the journey: I created functional deployment maps to visualize the entire change management process, illustrating how information flowed between teams and where it encountered bottlenecks.
Identifying pain points and opportunities: I identified recurring pain points, categorized them by root cause and impact, and recommended solutions such as:
Establishing clear ECO procedures
Improving ERP system usage
Standardizing documentation
Providing targeted employee training
Implementing inventory management reporting tools
Enhancing technology and software integrations
3 — Key insights
Understanding the process: I conducted an in-depth study of Engineering Change Orders (ECOs), which serve as the backbone for documenting and managing changes to product components, Bill of Materials (BOM), and customer requirements.
Bridging gaps across teams: I led workshops with Project Management, Engineering, and Operations to identify how siloed communication and unclear responsibilities were impacting timelines, costs, and quality.
Mapping the journey: I created functional deployment maps to visualize the entire change management process, illustrating how information flowed between teams and where it encountered bottlenecks.
Identifying pain points and opportunities: I identified recurring pain points, categorized them by root cause and impact, and recommended solutions such as:
Establishing clear ECO procedures
Improving ERP system usage
Standardizing documentation
Providing targeted employee training
Implementing inventory management reporting tools
Enhancing technology and software integrations
3 — Key insights
Understanding the process: I conducted an in-depth study of Engineering Change Orders (ECOs), which serve as the backbone for documenting and managing changes to product components, Bill of Materials (BOM), and customer requirements.
Bridging gaps across teams: I led workshops with Project Management, Engineering, and Operations to identify how siloed communication and unclear responsibilities were impacting timelines, costs, and quality.
Mapping the journey: I created functional deployment maps to visualize the entire change management process, illustrating how information flowed between teams and where it encountered bottlenecks.
Identifying pain points and opportunities: I identified recurring pain points, categorized them by root cause and impact, and recommended solutions such as:
Establishing clear ECO procedures
Improving ERP system usage
Standardizing documentation
Providing targeted employee training
Implementing inventory management reporting tools
Enhancing technology and software integrations
4 — Impact
The findings were presented to leadership, aligning them on the importance of communication in engineering change management. The flow maps and identified pain points provided clarity on where delays and inefficiencies occurred, enabling opportunities for improvement. My recommendations served as a guide to reduce errors, expedite processes, and improve cross-team collaboration.
Key takeaways from this project include:
Asking the right questions to uncover the real problem
Thoroughly documenting processes for effective analysis
Using visuals to simplify complex workflows
This project earned me my LEAN Six Sigma Green Belt and deepened my understanding of how clear communication can transform processes. It also shaped my approach as a designer, emphasizing the importance of bringing teams together, documentation, and making information accessible.
4 — Impact
The findings were presented to leadership, aligning them on the importance of communication in engineering change management. The flow maps and identified pain points provided clarity on where delays and inefficiencies occurred, enabling opportunities for improvement. My recommendations served as a guide to reduce errors, expedite processes, and improve cross-team collaboration.
Key takeaways from this project include:
Asking the right questions to uncover the real problem
Thoroughly documenting processes for effective analysis
Using visuals to simplify complex workflows
This project earned me my LEAN Six Sigma Green Belt and deepened my understanding of how clear communication can transform processes. It also shaped my approach as a designer, emphasizing the importance of bringing teams together, documentation, and making information accessible.
4 — Impact
The findings were presented to leadership, aligning them on the importance of communication in engineering change management. The flow maps and identified pain points provided clarity on where delays and inefficiencies occurred, enabling opportunities for improvement. My recommendations served as a guide to reduce errors, expedite processes, and improve cross-team collaboration.
Key takeaways from this project include:
Asking the right questions to uncover the real problem
Thoroughly documenting processes for effective analysis
Using visuals to simplify complex workflows
This project earned me my LEAN Six Sigma Green Belt and deepened my understanding of how clear communication can transform processes. It also shaped my approach as a designer, emphasizing the importance of bringing teams together, documentation, and making information accessible.