An industrial co-operative project between a manufacturing company and a university demonstrates how a large scale project from idea to trained organisation was carried through. The order management process was redesigned from push to pull, and the planning activities were moved to the shop floor through a multi faced role called a waterspider function assisted by an adjusted ERP system to obtain a user-friendly and simple IT environment. The methods applied to redesign were based on LEAN principles to eliminate waste and to enhance flow. The project involved the end to end supply chain. The challenge was to get commitment in the organization as well as to find a technical solution. A lot of effort was put into training the employees, which in the final run has demonstrated remarkable results.
Flow production, business process reengineering, LEAN manufacturing, MRP versus LEAN, intelligent manufacturing through employees.