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Discipline Counts: Raising the Bar for Lead Time, Cost Savings and Throughout
A private equity client engaged the CBS team to significantly improve the operational performance of a recently acquired company, a family-owned business with a history as a quality leader in the industrial equipment market. CBS targeted production costs, lead time and capacity/throughput as areas of improvement—and implemented business disciplines to help ensure sustainable results.
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Improving Productivity and Decreasing Costs
A labeling manufacturer lacked the capacity to meet its customers’ volume and mix requirements, resulting in costly additional shifts, selective outsourcing and loss of large client orders. CBS led a Kaizen event to analyze and improve the process, which reduced the average changeover by 60% and helped decrease the need for temporary workers and weekend shifts.
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Empowering the Center of Excellence
This manufacturer’s recently established Center of Excellence (COE) was struggling with poor schedule performance, cost overruns and quality issues. In response, CBS developed a balanced set of metrics to drive strategy and highlight gaps. CBS introduced team effectiveness training, team-based management techniques and a reorganized structure. The resulting improvements helped the COE underrun budgets and return over $15M to the business.
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Timing is Everything: Meeting Demand for Critical Product Lines
A designer and manufacturer of high-tech military products, this company was unable to meet customer demands, resulting in customer dissatisfaction and the potential for contractual penalties. CBS helped the company develop capacity tools for critical product lines, eliminated non-value-added activities and implemented a takt-based system that doubled shop capacity and reduced product lead time from 50 days to 13 days.
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Training the Workforce for Improved Performance
A manufacturer of wings and supporting aerostructures was experiencing high rates of employee attrition, which impacted delivery deadlines and revenue goals while compromising important customer relationships. An intensive CBS engagement helped the supplier implement a robust workforce training program, significantly reduce product defects and rapidly improve on-time delivery rates.
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