Showcase
Fortune 500 Aerospace Manufacturer
Current State:
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Lead times were excessive and impacting OEM and BTP business
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Had become uncompetitive in the marketplace
Tools:
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Value Stream Mapping
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Kaizen Events
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Cellular manufacturing
Results:
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Reduced lead times by 70%
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Established manufacturing cells
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Slashed cost to manufacture by 60%
Sports Equipment Manufacturer
Current State:
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New product to market lead times were too long
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Manufacturing quality and process needed improvement
Tools:
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Value Stream Mapping
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Kaizen Events
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Standard Work
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Kanban
Results:
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New product to market lead time reduced by 67%
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Quality reject rate went from 5.7% to <0.40%
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Implemented global procurement strategy
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Increased velocity and reduced cost to European marketplace
Diversified Automotive and Aerospace Manufacturer
Current State:
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Large inventories constricting flows and use of cash
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Long lead times impacting customer service
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Cost of product impacting sales
Tools:
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Value Stream Mapping
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Kaizen Events
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Standard Work
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Cellular manufacturing processes
to improve flow
Results:
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Slashed Inventories by $9M
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Attained 25% reduction in costs
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Increased Variable Contribution Margin by 5%
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Increased Operating Profit by $5M through global
manufacturing strategies
Coating Manufacturer
Current State:
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Sub par customer service
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Long lead times
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Large inventories
Tools:
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Kaizen Events
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Set-up Reduction
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Operational Strategy Deployment
Results:
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Reduced inventories by $5M
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Improved Customer Service to 97%
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Ramped up EBITDA by $11M
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Moved operating margins up to 35%
