Material Waste Reduction
Rapidly Capturing Manufacturing And Logistics Cost Reduction Opportunities At Ethnic Foodservice Products Manufacturer
Captured $1.2MM in operations run-rate savings in 12 weeks at an ethnic foodservice and retail private label products manufacturer by implementing shop floor management best practices. Gotham worked on the shop floor to: observe operations; identify potential improvement opportunities; provide immediate guidance to client personnel; and troubleshoot and pilot solutions. We improved line through from ~225 cases/shift to ~375 cases/shift, reduced fill weight by 3-7% to minimize overfill, reduce floor scrap by 50%; and eliminated expired rework scrap. To ensure sustainability and further improvements, we: trained client personnel, put in place process changes, tools, KPIs and reporting system; and identified/planned next set of improvement opportunities. Gotham also launched logistics savings capture by developing direct ship pilot and facilitating conversation between company sales teams and foodservice distributors.
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Operational Basics, Waste Reduction, and Productivity Improvements to Turn Around Declining Performance at Stationary Products Manufacturer
Identified $2+MM in opportunity from focusing on operational basics, e.g., measurement & reporting, material and labor procedures, and production scheduling. Implemented a paper waste measurement system to identify major sources of loss and then addressed root cause issues (e.g., setup waste, end-of-roll waste, material handling waste, and in-process waste). Within 6 months, material waste more than halved (from the original 40%+ levels) and labor productivity went up 15%.
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Creating Product/Process Specs and Implementing Performance Tracking System to Enhance Throughput and Operations Consistency at Foodservice Meat Products Manufacturer
Captured over $10 million in waste and throughput opportunities (15% reduction in total operating and materials costs) by identifying root causes, developing new operating procedures, and establishing KPIs.
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Assessing Manufacturing Capabilities and Scalability to Support Aggressive Growth Projections at Startup Green Building Materials Company
Analyzed operations and cost structure of this startup manufacturer projected to grow to over $80MM in sales in 5 years. Reviewed manufacturing equipment and operations, built a bottom-up cost model for current and future costs, and established requirements for scaling up the operations. The operational due diligence revealed necessary improvements to meet the very aggressive growth forecasts, as well as opportunities for cost reduction. PE client deferred investment.
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Finding and Valuing Cost Reduction Opportunities at Global Tier 2 Automotive Components Supplier
Conducted opportunity assessment at Tier 2 Automotive Parts supplier with manufacturing locations in 4 countries. Identified $6-9MM in short-term and $27-37MM in longer-term cost reduction opportunities. Near-term opportunities included improving efficiency of US operations and re-sourcing materials and components from lower cost locations. Longer-term opportunities involved closing a European facility, migrating labor-intensive products from the US to Mexico facility, and building up a Chinese JV to supply all Asia product needs. Identified opportunities far exceeded management plan.
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Identifying and Quantifying Potential Network and Standalone Improvements at Specialty Jewelry Manufacturer and Printer
Conducted diagnostic to identify areas of opportunity and potential value of operational initiatives. Identified $6-8MM opportunities in jewelry manufacturing and $4-6MM in book printing via application of lean manufacturing, automation, improved customer service, and network optimization. Established a 100-day plan to jump start the opportunity capture. Post-acquisition, using 100-day plan, management able to migrate manufacturing to lower cost countries, outsource product finishing, and close an underperforming facility, leading to the capture of the outlined savings within 12 months.
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