Breaking the Silos: Real-Time Control Tower Accelerates Batch Release

What Was Actually Happening

Through detailed process mapping and business process mapping, Gemba walks and analysis of data, systems, and management practices, we found that the issue wasn’t lack of data rather it was lack of trust and collaboration:

• Different departments operated in silos with little visibility into one another’s priorities or progress and resulting in poor cross-functional coordination
• Although process data was available electronically, employees recreated it in personal spreadsheets that they “trusted more”
• These spreadsheets were not shared across departments, creating fragmented versions of the truth
• Management reviews relied on manually compiled charts, often outdated and inconsistent with validated system data
• Status updates for batch release required input from several departments, but there was no single coordination mechanism to drive accountability or timely decisions

In effect, the site had the data but not the system, mindset, or structure to use it effectively.

What We Changed

Designed and implemented a Supply Chain Control Tower, which is a structured, data-driven management system and includes a dashboard. Our approach focused on breaking down silos to drive daily alignment and improve transparency and accountability:

• Cross-Functional Daily Meeting: Mandatory attendance from Manufacturing, Quality, Planning, and Supply Chain leadership
• Real-Time Dashboard: Automated data feed from validated electronic systems, eliminating manual spreadsheet updates
• Structured Action Management: Clear, enumerated list of daily actions to ensure adherence to the supply plan and timely resolution of deviations from that Plan
• Escalation Framework: Defined decision pathways for issues that could not be resolved within the meeting
• Time-Boxed Sessions: Tight meeting durations to maintain senior management engagement and discipline

What It Delivered

• ~3.5 FTE time freed by eliminating manual dashboard creation and spreadsheet maintenance
• Single source of truth established across all functions, increasing transparency and alignment
• Improved batch release coordination and faster decision-making across departments
• Greater accountability and cross-functional visibility, with leaders addressing issues in real time rather than after the fact
• Best of all – greater cooperation between different teams