Case Studies

FACTORY

FACTORY DESIGN & RELOCATION

We developed a new layout and operating guidelines based on Lean Principles for their new manufacturing and headquarters facility.

We developed a new layout for their new manufacturing and headquarters facility, and helped plan and execute their move.

PRIVATE EQUITY

PRIVATE EQUITY

This operations assessment evaluated warehouse operations to determine effectiveness and improve rollout of new automation and process improvement.

6 weeks, 2 person team
5 key areas of deficiency
25 best practices tagged for universal deployment
16 new improvements identified

Our factory productivity assessment considered factory productivity and identified improvement projects.

8 weeks, 2 person team
6 plants evaluated
124 heads reduced (9%)
About $8 million in savings
Plants agreed with actions

Operations transformation for profit and cashflow improvement

2 yrs as EVP of global operations
2x EBITDA to 10% on sales
consolidated network to 30 facilities with 3 newly built
Launched Lean across plants

DIAGNOSTIC EVALUATIONS

DIAGNOSTIC EVALUATIONS

This operations assessment evaluated warehouse operations to determine effectiveness and improve rollout of new automation and process improvement.

6 weeks, 2 person team
5 key areas of deficiency
25 best practices tagged for universal deployment
16 new improvements identified

Our factory productivity assessment considered factory productivity and identified improvement projects.

8 weeks, 2 person team
6 plants evaluated
124 heads reduced (9%)
About $8 million in savings
Plants agreed with actions

BUSINESS UNIT STRATEGY

BUSINESS UNIT STRATEGY

Analysis of business profitability and business unit improvement.

12 weeks, 1 person team
Corrected product profit rates
Identified high cost root cause
Helped renegotiate pricing
Returned division to profit

Market entry assessment of market segment size, profitability, and attractiveness.

2 weeks with 1 person team
Porter’s 5 Forces Model
Competitor Profiles
Market Size Estimate
Market Profitability Estimate

BUILDING OPERATIONS

BUILDING OPERATIONS

This complete operations transformation improved profit and cashflow.

2 years as EVP of global operations
2X EBITDA to 10% on sales
Consolidated network to 30 facilities with 3 newly built
Launched Lean across plants

Transformation of automotive manufacturing and assembly plant.

6 months with 8 person team
Improved productivity 25%
Saved $100 million in cost
First Time Thru quality improved from 20% to 70%

INVENTORY MANAGEMENT

INVENTORY MANAGEMENT

Developed a scoring method for measuring criticality of parts along multiple dimensions.

Determined the true performance levels and costs to operate the spare parts and material management processes for the MBTA.

Guided MBTA through an outsourcing process to competitively bid transition and ongoing operation of their Material Warehousing & Distribution Activities to a qualified 3PL.

NETWORK OPTIMIZATION

NETWORK OPTIMIZATION

Analyzed the global network of manufacturing plants and developed a new optimized plan.

Developed a new optimized plan capable of better serving customers while reducing fixed and operating costs.

Built a new strategy of global network optimization and performance improvement to reduce costs and return the company to financial health.

Built an improvement strategy optimizing the network and improving the internal performance of the plants.

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