Client Results
Real outcomes from the factory floor. We focus on metrics that matter: Margin, Throughput, and Quality.
30% Throughput Increase in 90 Days
Automotive / Transport•Utility Trailer OEM
Trailer Manufacturer Transformation
The Challenge
The plant was gridlocked. Welders spent 40% of their day looking for parts. WIP was piled everywhere.
Our Approach
We applied the Stabilize phase of our roadmap, implementing strict WIP limits and visual material kits.
Key Metrics Achieved
30% Throughput Increase
$2M Inventory Reduction
Zero Missed Shipments in Q4
15% Scrap Reduction
Plastics•Tier 2 Auto Supplier
Scrap Reduction in Injection Molding
The Challenge
Operators were running bad parts for hours because measurement checks were infrequent and disconnected from flow.
Our Approach
Implemented the DCF Measurement Pillar. hourly scorecards and "stop-and-fix" protocols.
Key Metrics Achieved
15% Scrap Reduction
12% Energy Savings
Operator Retention Improved