Case Study: Performance Improvement Expertise - Manufacturing

 Challenges we solve:

• Excessive manufacturing costs
• Lack of systematic business processes
• Capacity constraints
• Inventory challenges
• Sub-optimal operations
• Reactive front-line management
• Stagnant or declining revenue growth
• Inability to maintain safety and quality
• Skilled labour shortage

 Client case studies:

Improving EBITDA while scaling growth

Large medical device manufacturer

Case for Change

With the organization experiencing 20 percent growth year-over-year, the leadership team faced difficulties scaling the business.

Solution

Using process improvement techniques in line balancing, scheduling, scrap reduction, and active supervision, the project team reduced costs and increased output.

Result

With the right supports in place, the organization was able to make an EBITDA improvement of $1.7 million by the end of the project. Focused on reducing non-value-added time, labour costs alone were reduced by 15 percent; the remaining savings were achieved through improved material usage.

Successfully preparing for succession

Mid-sized kitchen and bath manufacturer

Case for Change

Historically operating at a high volume, the organization achieved significant success. But with a decline in home builds and consumer preferences moving towards custom goods, the organization was unable to maintain its quality or deliver on

Solution

We applied Lean Six Sigma methodologies and best practices to increase capacity by more than 50 percent. This included better production scheduling and enhanced performance measurement, including intra-day monitoring and control. By closing gaps, eliminating waste, reducing downtime, and increasing output, the team was able to surpass saving expectations.

Result

Without spending any money on capital investments, the organization saved $1.5 million within nine months of the engagement.