How Johnstech Achieved On-Time Delivery Despite Market Volatility
Discover how Johnstech, a global leader in semiconductor testing, navigated unprecedented market disruptions to not only maintain but exceed its ambitious delivery goals. This case study reveals the strategies and tools they used to achieve exceptional operational agility and reliability, even when faced with extreme supply chain variability.
The Challenge
The global chip shortage and subsequent market fluctuations created operational hurdles for Johnstech. The company had to manage a shift in order types, from primarily engineer-to-order (ETO) and make-to-order (MTO) to a surge in make-to-stock (MTS) spares. This volatility put immense pressure on materials management, capacity planning, and their ability to maintain industry-leading lead times without overwhelming their production systems.
The Solution
For over two decades, Johnstech has relied on SyncManufacturing®, an advanced planning and scheduling (APS) system from Synchrono. While their ERP system manages transactions, SyncManufacturing® provides the real-time visibility and control needed for dynamic production scheduling.
The system allowed Johnstech to:
- Gain a single, intuitive interface for managing complex production schedules.
- Integrate seamlessly with their ERP (Microsoft 365) to automate order processing.
- Match each new order to available factory capacity before confirmation to prevent overselling.
- Easily manage constraints, including skilled labor, materials, and machine capacity.
“I can see everything in the system. It’s like being seated in a cockpit. I don’t need to go anywhere to manually check on anything.”
Lonnie Kunze, Master Scheduler | Johnstech
The Results
By leveraging SyncManufacturing®, Johnstech transformed its scheduling process from a reactive challenge into a proactive competitive advantage.
Improved On-Time Delivery
Consistently achieved a 98-99% on-time delivery, surpassing their 95% goal.
Reduced Lead Times
Cut average lead times to 3-4 weeks, compared to the industry average of 5-8 weeks.
Increased Efficiency
Gained deep visibility into production, enabling them to make smarter staffing and procurement decisions, saving time and resources.
“Everybody says their people are their most important assets, but ours really are. Delivering quality requires sophisticated equipment and employees with experience and specific skill sets. It’s so important for us to use a scheduling application like SyncManufacturing® that lets us see our people constraints as well as machine and materials.”
Lonnie Kunze, Master Scheduler | Johnstech
See SyncManufacturing® in Action
Ready to improve on-time delivery and cut your lead times in half? Schedule a personalized demo of SyncManfacturing® today and see how you can transform your operations.