Case Studies

A leading manufacturer of motorcycles was launching a new product line that required a key engine component to be manufactured domestically - this was one of the performance-defining components and was going to give a competitive advantage to the manufacturer. Under a window of 6 months, the team was able to ideate, design, develop and deliver the component with a domestic vendor meeting Quality and Delivery expectations while reducing the cost of the component by~60% vs the import option  

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A global life sciences technology company's key manufacturing business unit was consistently seeing an uptick in demand for multiple quarters and the S&OP team forecasted similar growth for the next 12 months. With plants running 3-shift operations, the goal was to maximize utilization. The team started with a value stream map, reduced cycle time of the bottle-neck operation by 40% (series of kaizens) and implemented a scheduling optimization tool that optimized daily production plans. These initiatives drove the utilization by 25% thereby providing a solid capacity and supply plan.

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A leading electrical component manufacturer wanted to implement the lean philosophy across its enterprise and was looking to establish a business system to drive profitability. Through a series of lean transformation initiatives in manufacturing, finance, CX and technology the organization created an operating model and a problem-solving methodology that drove >$15M towards FCF and improved overall productivity by 30%. The team further created a strategy deployment process that allowed the organization to focus breakthrough initiatives and to create a culture of executing with agility.

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