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Proven Results

Our Lean methodologies have delivered measurable improvements across diverse industries and company sizes. From Fortune 500 aerospace manufacturers to specialized coating companies, our tailored approach consistently drives operational excellence and financial performance.

The following case studies demonstrate our commitment to practical results and sustainable improvements that transform businesses.

Fortune 500 Aerospace Manufacturer

Current State Challenge:

The company was experiencing excessive lead times that made them uncompetitive in the marketplace, struggling to meet customer demands and maintain market position.

Lean Tools Applied:
  • Value Stream Mapping
  • Kaizen Events
  • Cellular Manufacturing
Results Achieved:
  • 70% lead time reduction
  • Established efficient manufacturing cells
  • 60% manufacturing cost reduction

Sports Equipment Manufacturer

Current State Challenge:

Long new product to market times and significant quality issues were impacting competitiveness and customer satisfaction.

Lean Tools Applied:
  • Value Stream Mapping
  • Kaizen Events
  • Standard Work
  • Kanban Systems
Results Achieved:
  • 67% reduction in new product to market lead time
  • Quality reject rate dropped from 5.7% to <0.40%
  • Implemented global procurement strategy
  • Improved European market velocity and cost structure

Diversified Automotive and Aerospace Manufacturer

Current State Challenge:

The organization was burdened with large inventories, extended lead times, and high product costs that were eroding profitability.

Lean Tools Applied:
  • Value Stream Mapping
  • Kaizen Events
  • Standard Work
  • Cellular Manufacturing
Results Achieved:
  • $9M inventory reduction
  • 25% cost reduction
  • 5% increase in Variable Contribution Margin
  • $5M Operating Profit increase through global manufacturing strategies

Coating Manufacturer

Current State Challenge:

Poor customer service levels, extended lead times, and excessive inventories were limiting growth and profitability potential.

Lean Tools Applied:
  • Kaizen Events
  • Set-up Reduction
  • Operational Strategy Deployment
Results Achieved:
  • $5M inventory reduction
  • 97% customer service level achievement
  • $11M EBITDA increase
  • Operating margins increased to 35%

Ready to Transform Your Business?

These results demonstrate the power of properly implemented Lean methodologies. Every organization is unique, and we tailor our approach to deliver sustainable improvements that align with your specific goals and culture.

Contact us to discuss your challenges