"Future state" vision delivers immediate results
Ice Cream Company ($1+ billion): Developed a "future state" vision for dairy processing that identified opportunities to improve performance and standardize operating practices which will save $2.1 million annually with a total capital investment of $0.5 million. Implemented "quick wins" which will generate savings in excess of $0.7 million per year.
Global strategy launched to save over $1 billion
Beverage Company ($32 billion): Helped devise and launch a global improvement strategy which resulted in a 5% decrease in Cost of Sales at the pilot site. Key activities included designing the program (e.g., organization structure, implementation approach, capability building, etc...), conducting a site diagnostic, coaching project leaders on implementation activities, and implementing a CI steering committee process. The global effort is on pace to generate annual savings of over $1 billion per year.
Reconfigured assembly process improves labor efficiency
Electronics Company ($10 billion): Established a flexible production system through redesigned line layouts, mixed model production, and standard work for multiple staffing situations based on customer demand which improved shop floor productivity by 17%.
Flexible labor strategy delivers higher productivity
Ice Cream Company ($1+ billion): Helped design a flexible labor system for the Finished Goods warehouse which reduced labor costs by ~$1.9 million despite an increase of over 5% in shipped cases. Also, implemented standard work, visual management, and a performance management system to increase productivity in the Raw Materials warehouse by over 25% which generated over $500 k in annual savings.
First profitable year for a business unit saves US jobs
- Automotive Supplier ($13 billion): Helped a Tier 1 supplier reduce operating costs by $5 million per year allowing the department to make a profit for the first time which compelled the management team to cancel plans to move the operation to Mexico. The cost reduction was achieved through cellular manufacturing using a pull system and rigorous performance management (e.g., KPIs, standard work, formal reviews).
Supply chain study delivers results
Ice Cream Company ($1+ billion): Developed various scenarios to relieve supply chain constraints while also diversifying assets with minimal capital investment to support the company's planned organic growth. Presented findings to the executive leadership team along with a recommended strategy which was ultimately adopted and allowed the company to avoid a significant capital investment while maximizing its strategic options going forward.