Building Better Businesses

Comprehensive intervention focusing on changing the production schedule and shift pattern to reduce energy cost, implementation of visual controls and an internal milk-run system, reassignment of team members to value-adding positions, improved maintenance and process flow optimization Project timeline: 26…

Total restructuring and standardization of operational systems at North American and European Distribution Centers. The effort included zone picking, deployment of inexpensive trams following short pick routes, relocation of inventory to enhance pick density, implementation of direct pick-to-box or pick-to-pallet…

Comprehensive intervention focusing on improving production and packing cell design, distribution centre systems improvements including a visual kanban system and an internal milk-run system, various process kaizen/LIFT events, scrap reduction, process yield improvements, material and energy cost savings. Project timeline:…

Comprehensive multi-location intervention focusing on value stream restructuring, cell formation, labour balancing (direct and indirect), improving production cell design, rapid changeover, elimination of capital expenditure needs, introduction of visual controls and energy savings. Project timeline: 35 weeks Project cost: $327,995…

Comprehensive intervention focusing on picking process optimization, warehouse layout reorganization, reduction of capital expenditure needs, development of standardized work, sort and pack cell improvements and introduction of visual controls. Project timeline: 20 weeks Project cost: $271,969 Project annualized savings: $1,200,000…

Comprehensive intervention improving capacity of labour-intensive X-ray and FPI inspection lines, reducing operating shifts from 4 to 2. Improvement of casting OEEs from 50% to 80%, enabling additional reduction of operating shifts. Plant manager coaching to establish highly effective problem…

Comprehensive intervention focusing on inventory reduction, improvement of casting and X-ray operations, automation of all casters, elimination of the need for temporary labour, and several LIFT events to improve material handling and process flow. Project timeline: 12 weeks Project cost:…