Business Issue Complex Acquisition Integration Three separate companies were acquired by a private equity firm within 6 months, with none of the companies identified as the ‘platform company.’ The challenge was to integrate the three companies into a single operating company as fast as possible. The task included creating common processes as needed and to integrate the parts into a cooperating … [Read more...]
All Case Studies
Baseline Approach Results in Over $4m Saved
Business Issue Baseline Project A pharmaceutical company had a profitable product line coming off patent and needed to make up for the coming loss of revenue. While new products were coming online slowly, additional changes were needed to meet the challenge of maintaining or growing EBITDA contributions. It was determined that cost saving and inventory reduction opportunities needed to be … [Read more...]
Unleashing Potential Using Lean Techniques
Business Issue Our client’s very low production volume failed to meet the needs of its customers to provide laser engraving on a variety of drink ware products. Production volume was running at 66,000 units per month against a target of 500,000 units per month. Other key metrics included the following:
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Drying time of the paint-like product exceeded the 2.5 hours promised but instead … [Read more...]
A Lesson Worth Millions: Learning and Applying Lean While Earning a 10X Return
Business Issue A Fortune 500 service solutions provider of high-end electronics was facing decreasing revenue due to increasing reliability of its original products. Key issues were:
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Culture: Do whatever it takes or costs in the near term with insufficient focus on future impact and little focus on Continuous Improvement
Inventory: Excessive holding and obsolescence costs beyond … [Read more...]
Industrial Distribution Company Moves to Single Best-In-Class VMI Using Strategic Software Selection Method
Business Issue An industrial distribution company recently acquired two similar size companies, and wished to move to a single customer Vendor Managed Inventory (VMI) delivery process. Approach Used Flow Consulting pulled key members of all three firms together and facilitated a kaizen that captured the current processes being used by all three entities. The team developed a process that all … [Read more...]
Lean Concepts Save $25M Warehouse Capacity Expansion
Business Issue An automotive OEM parts distributor covering a five-state area was running out of room at its single 300,000 sq. ft. distribution center. The distributor was considering a $25 million expansion to be completed within 18 months. Current warehouse capacity exceeded 95.8% of available space. This left little room for new products or efficient part locating. The distributor asked Flow … [Read more...]
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