Case Studies
Optimizing Production Efficiency for a Medical Equipment Manufacturer
Challenge: A medical device manufacturer faced inefficient production layout and material flow, leading to high cycle times and low production output. There was no standardized process for material availability.
Solution: Our Team of experts conducted a 3-day Kaizen event to redesign the production layout and implement a kitting syste
Challenge: A medical device manufacturer faced inefficient production layout and material flow, leading to high cycle times and low production output. There was no standardized process for material availability.
Solution: Our Team of experts conducted a 3-day Kaizen event to redesign the production layout and implement a kitting system. 3D-printed tool improvements were also implemented. Additionally, a real-time shop floor management system was developed.
Results: The project resulted in a 45% cycle time reduction, exceeding the 37% target. Output increased by 60%, and labor costs were reduced by $5 per unit. The solution was fully implemented within 30 days.
Optimizing Capital Management for a Large Commercial Landscaping Firm
Challenge: A large commercial landscaping company struggled with inefficient capital management due to a lack of structured budgeting, rebate management, expense tracking, and integrated financial controls. Disconnected ERP, procurement, and fleet management systems further exacerbated the issue. Poor inventory control led to a potential
Challenge: A large commercial landscaping company struggled with inefficient capital management due to a lack of structured budgeting, rebate management, expense tracking, and integrated financial controls. Disconnected ERP, procurement, and fleet management systems further exacerbated the issue. Poor inventory control led to a potential write-off of $880,000.
Solution: Our team implemented BI reporting for spending visibility and standardized inventory tracking across 304 branches. Approval workflows were established, and real-time asset tracking was integrated with the ERP system. Standard Operating Procedures (SOPs) were also developed for consistent capital management.
Results: The project prevented $880,000 in write-offs and accelerated production cycles by 25%. Real-time tracking for assets and spending was enabled, and an audit-ready capital management framework was established.
Transforming Manufacturing Operations through Leadership & Process Optimization
Transforming Manufacturing Operations through Leadership & Process Optimization
Challenge: A manufacturing plant faced safety hazards, quality failures, and a lack of communication. These issues led to frequent injuries, inconsistent product dimensions, excessive rework, and poor supplier quality.
Solution: The team prioritized safety by establishing strict safety protocols. A "quality over quantity" approach was
Challenge: A manufacturing plant faced safety hazards, quality failures, and a lack of communication. These issues led to frequent injuries, inconsistent product dimensions, excessive rework, and poor supplier quality.
Solution: The team prioritized safety by establishing strict safety protocols. A "quality over quantity" approach was implemented using a Formula 1 pit stop strategy. Supplier quality management was enhanced through an inspection process, reporting, and supplier scorecards.
Results: The plant achieved near zero major safety incidents following protocol enforcement. Quality improved, supplier control was strengthened, and standardized performance monitoring was introduced.