Skip to main content
Capability

Quality Systems

banner
Manufacturer of Industrial and Commercial Machines
Quality Management Program to Ensure High Returns from Quality Assurance Spending at Leading Manufacturer of Industrial and Commercial Machines

Created a new quality management program to raise the overally effectiveness of quality spending, with key elements including: alignment of quality KPIs with customer needs and optimal process decision points; proactive management of quality assurance up and down the supply chain; accurate information on the true costs of quality functions to facilitate decision making. The program comprised vendor certification, product quality standards, preventative maintenance, inspection and testing processes, timely problem reporting and resolution, warranty processing, and quality performance and tracking. Six- month checkup of client-led program implementation found significant reduction in the cost of quality.

Show Details
banner
Precision Medical Device Component Manufacturer
Rapid Backlog Reduction and Sustainable Delivery System at Precision Medical Device Component Manufacturer

Rapidly reduced backlog and created a robust delivery system. Backlog reduction effort included rolling out prioritized schedule, developing and implementing debottlenecking strategies, creating a cross-functional team resolving issues that were stopping scheduled jobs. Robust delivery system initiatives included: 1) turning on the planning and scheduling functionality of the ERP/cleaning up system data and parameters, developing SOPs for data entry, training the workforce on the SOP; 2) improving the accuracy of time estimates by revamping engineering process; and 3) reducing quality defects by 20%. Within 3 months, on-time performance improved from 59% to 93% while lead time shrunk from 13-16 weeks to 10 weeks, with backlog reduced in half.

Show Details
banner
Cookie Franchiser
Assessing Operations-related Acquisition Risks at Leading Cookie Franchiser

Conducted 1-week operational due diligence of ingredient manufacturing operations for a quick-service franchise company, targeting labor practices, safety and environmental compliance, and inventory practices. Reviewed of labor policies, including work rules, attendance policies, and basic compliance with overtime, lunch, and break rules. Determined that the facility had solid risk management operations, and recommended minor improvements in quality assurance and material handling. The PE firm purchased the company and followed through on recommendations from operational due diligence.

Show Details
banner
Ethnic Foodservice Products Manufacturer
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.

Show Details
banner
Coffee Roaster and Distributor
Identifying Consolidation Opportunities and Creating Roadmap for Professionalizing Operations to Support Future Growth at Regional Family-owned Coffee Roaster and Distributor

Conducted a 3-week operational due diligence to establish a robust fact base of cost and operational performance in a data-poor situation, identify consolidation opportunities, and provide a fact-based, actionable plan for post-acquisition value creation, including:  delivery and service route optimization to eliminate 30-40% of current routes; brewing equipment CapEx reduction through better deployment of used equipment; warehouse consolidation; sourcing efficiencies; SKU complexity management and inventory reduction; and professionalization of roasting and supply chain operations. Gotham’s findings enabled the client to close the transaction with confidence; the company started capturing identified opportunities within a few weeks of the deal closure. 

Show Details
banner
Branded Ethnic Foods Manufacturer
Assessing Operational Scalability to Support Targeted Growth at Family-owned Branded Ethnic Foods Manufacturer

Built operational performance fact base and cost model for due diligence of an entrepreneurial company. Effort included: first-hand observation of operations, management interviews, data collection and synthesis, equipment condition and capex requirement assessment, food safety review, and interviews with potential co-packers. Established that:  the existing plant can meet the buyer's target of growing the business 2-3X current volume; identified 5-6 viable and interested co-packers; identified opportunities to reduce cost per case by 16-17.5%; and provided a road map for improving operations. The PE firm is in process of closing the deal.

Show Details

Industry Expertise

 
banner
Consumer
 
banner
Food & Beverage
 
banner
Healthcare
 
banner
Industrials
 
banner
Energy
 
banner
Services

Want to learn more about how Gotham can help you with value creation?