Recent Projects

Here are quick summaries of some of the more impactful projects we have led. If you want more details, contact us to set up a call.

Projects are presented in a consistent linear style of Problem > Analysis > Solution.

Project 1

Cycle time of a manufacturing process was excessive, resulting in overtime costs, excess inventory, and missed deliveries

Discovered that a specific operational step was a bottleneck

Optimized bottleneck process step. Saved $375,000 with a potential cost avoidance of $1.1 million

Project 2

Product Warranty was significantly higher for one product than others in the family

Discovered defects in the locking mechanism design and a battery that was not performing

Improved locking mechanism design and specified a better battery. Changes resulted in $1.2 million in warranty savings

Project 3

Product Demand Forecasting process was only ~45% accurate, resulting in excess inventory, longer lead times, expediting fees, and charges from customers for late deliveries

Discovered longer than necessary cycle time of monthly process, lack of statistical elements or market factor analysis to forecasting process

Built statistical model for Forecasting. Reduced cycle time by 19 days. Improved accuracy to 90%, saving nearly $1 million per year

Project 4

Headquarters office processes were manual, resulting in errors, long completion times, excess email and paper waste

Designed 6 key business processes to be automated within existing PLM tool

Through implementation of automated workflow designs, eliminated over 3000 pieces of paper, 121 miles of walking and over 5000 emails annually