Typical Results

Example Client Results

Integrated Stainless Steel Mill (Multi-Plant):
$120,000,000 Inventory Reduction
36% Reduction of Lead Times
On-Time Delivery from 62% to 90%
$20,000,000+ Annual Cost Savings
Accomplished in 18 Months!

Electric Motor Manufacturer:
Manufacturing Lead Time Reduced from 4 Days to 3 Hours
95% Reduction in Work-In-Process Inventory
90% Reduction in Completed Sub-assemblies
Space Requirements Reduced by 30%
Complex Scheduling System Replaced with a Simple Linear Pull
Accomplished in 3 Months!

Mail Order Company:
Lead Times Reduced from 2 Weeks to 4 Hours
Inventory Reduced by 60%
Output Per Sq Ft Floor Space Tripled
20% Productivity Gain
Accomplished in 6 Months!

Medical Equipment Manufacturer:
Lead Times Reduced by 87% from 8 Weeks to 5 Days
Inventory Reduced by $1,700,000 (41%)
60% Improvement in Quality
On Time Completions Went from Virtually "Never" to a Consistent 100%
Accomplished in Six Months!

Street Sign Manufacturer:
On Time Delivery Performance Improved from 65% to 99%
Lead Times Cut from 2 Weeks to 3 Days
40% Space Gain
Accomplished in 3 Months!

Label Products Producer:
Setup Time Reduced 72%
Labor Requirements Reduced 33%, While Sales Increased 20%
Accomplished in 12 Months

Motor Manufacturer:
90% Improvement in Productivity
90% Improvement in Quality
Moved From Weekly Schedule to Daily Schedule
Accomplished in 3 Months!

Defense Contractor:
Two Week Lead Time Cut to One Day
54% Reduction in Floor Space
52% Reduction in Rejects
100% Daily Schedule Attainment
Complex Scheduling System Replaced with Simple Kanban Controls
Accomplished in Four Months!

Integrated Carbon Steel Mill (Multi-Plant):
Inventory Reduced by $30,000,000
Lead Times Cut by 30%
Late Deliveries Cut by 67%
$6,000,000+ Annual Cost Savings
Accomplished in 12 Months!

Business Mail Order Company:
Total Inventory Reduced 67% from $6.0 million to $2.0 million
Operating Profit Increased from 9% to 18%
On Time Delivery Improved from 15% to 92%
Manufacturing Floor Space Reduced 40%
Accomplished in 12 Months!

Electrical Components Manufacturer:
Total Plant Inventory Reduced 20%
WIP Inventory Reduced 54%
Lead Times Reduced from 15 Days to 5 Days
Accomplished in 3 Months!

Tin Plated Carbon Steel Mill:
WIP Inventory and Cycle Time Cut By 60%
Total Inventory Reduced by $15,000,000
Average Lot Size Cut by 65%
Average Coil Mass Increased by 9%
On-Time Delivery Raised from 55% to 95%
Customer Complaints Cut by 65%
Profitability Increased by $5,000,000 PER MONTH
Accomplished in 10 Months!

Industrial Fuse Manufacturer:
Six Day Lead Time Cut to One Day
40% Reduction in Floor Space
75% Reduction in Total Inventory
100% Daily Schedule Attainment
Accomplished in Four Weeks!

Integrated Carbon Plate Mill:
Inventory Reduced by $8,000,000 (40%)
On Time Delivery from "Worst" to "First" in Their Industry
$3,600,000 Annual Productivity Gain
Accomplished in 4 Months!

Stainless Steel Finishing Plant:
Total Plant Lead Times Reduced 48%
On Time Delivery Performance Improved From 65% to 92%
External Finished Goods Warehouse Eliminated (no longer required)
Coil Damage Reduced 86%
Accomplished in 8 Months!

Aluminum Finishing Plant:
$18,000,000 Inventory Reduction
Total Plant Lead Times Reduced 22%
$2,200,000 Annual Productivity Gain
Accomplished in 8 Months!

Food Products Producer:
60% Reduction in Finished Goods Inventory
One Distribution Warehouse Shut Down (no longer required)
Lost Sales Due to "Out of Stock" Reduced 95% from $12,000/day to $600/day
Process Yields Improved From 90% to 99%
Setup Time Reduced From 3 Hours to 25 Minutes (86%)
Replenishment Cycle Reduced From 11 Days to 4 Days (64%)
Accomplished in 9 Months!