Production Planning & Scheduling
Network-wide Operating System to Turn Around Performance at Foodservice/Co-pack Juice Company
Turned around plant performance by implementing basic plant operating system (downtime, waste, and scheduling). $600K in run rate cost savings captured by the end of the 6-week engagement, with tools and processes in place to capture the rest. Building on the initial success, rolled out the network-wide standard operating procedures to the other 2 plants during an 8-week Phase II effort with additional savings of $2-2.5MM expected. Company generating record EBITDA (60+% improvement in EBITDA) and the PE firm decided to market the company for an exit.
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Enhancing Forecasting, Planning, and Product Lifecycle Management in Post-merger Environment at Leading Sporting Safety Equipment Company
Assisted 4 client teams and trained client personnel during a post-merger replenishment system enhancement and inventory reduction effort. Developed a centralized inventory and planning model by merging information from 2 separate operating entities. Achieved $8+MM reduction in inventory in 9 months.
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New Planning/Delivery Capabilities to Turnaround Customer Service/Delivery Performance at Leading Industrial Hardgoods Manufacturer
Led diagnostic-based effort culminating in enhanced planning and delivery capabilities: short-term tactical prioritization to overcome to overcome significant backlog; new planning system parameters; customer-oriented delivery strategy, including fast-ship program; shop-floor prioritization mechanisms (fixed schedule); measurement/tracking and reporting scheme for planning and production; ultimate migration to integrated MRP system. Fast- ship SKU program reduced order-to-delivery cycle from 2+ weeks to 1 day; $10MM backlog reduced to $2.5MM (including future orders) within 3 months.
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Rapid Reduction In Delivery Backlog at Leading Industrial Goods Manufacturer
Identified quick tactical solutions to address process issues responsible for delivery backlog. Created a backlog prioritization tool to identify and value component shortages that permitted prioritization of work orders and purchase orders. Achieved backlog reduction by more than two-thirds in short finished goods in 5 months.
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Harvesting Opportunity from Performance, Capability, and Cost Structure Enhancement at South American Industrial Goods Manufacturer
Identified specific actionable opportunities (cost, service, and quality) to capitalize on post-merger opportunities. Created plan to capture significant near term and longer term performance, capability, and cost structure enhancements. Management-led execution targeted to result in $2MM in cost, service, and quality savings (on a cost base of $5.5MM).
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Helping Boost Engine Plant Productivity Through Scheduling, Layout, and Product Strategy at Big 3 Automotive Company
Increased overall profitability by improving productivity by 36% at the bottleneck engine plant which was later named the most productive plant in the Harbour Report. Implemented a new scheduling system, flow-balanced the bottleneck line, and developed a strategy for product standardization and consistent material handling. $400MM in additional profit realization was enabled.
