Business Issue Pharmaceutical company facing significant challenges to cut its manufacturing costs. Approach Used Flow consultants performed an "Accelerated Problem Solving" workshop to analyze processes and quickly find and deliver opportunities for yield–improvements in mixing and packaging processes. Results Within two weeks the Flow workshop delivered $75,000 in annualized savings and … [Read more...]
All Case Studies
Slow Sales Growth/Lengthy Product Development
Business Issue An extremely successful producer of kitchen gadgets and household tools was experiencing lengthening product–development cycle times and slowing rate-of-sales growth. Approach Used Flow consultants performed a "Business Baseline" to analyze key contributors to the problem, and redesigned the organization structure into product–development teams, facilitated … [Read more...]
Product Specs/Customer Timing for Technology Start Up
Business Issue A technology start–up division of a major U.S. manufacturer needed clear definition of product specifications to meet customer needs and to better understand the timing of customer requirements. Approach Used Flow consultants collected extensive customer information through face-to-face and telephone interviews and electronic and web-based surveys. This database of information … [Read more...]
Production Costs Erode Margins
Business Issue A global manufacturer of pharmaceutical products was experiencing frequent packaging–line stoppages of a common over-the-counter cough syrup. Production costs had risen to erode margins on this product. Approach Used Flow consultants collected data in which line stoppages were recorded for cause, location and duration. A kaizen team was assembled whose goal was to … [Read more...]
Lengthy Cycle Times and Excessive Inventory
Business Issue Automotive original equipment manufacturer believed that its brake-puller cycle times are far too long and that its inventories are excessive. Approach Used Flow consultants used "Lean" principles and a kaizen session, to move from a process–centered product flow, to a product–focused cell. Results Flow Consulting reduced production costs on a $47 unit by $6.17. They also … [Read more...]
Slow Manufacturing Cycle and High Product Costs
Business Issue Microchip test equipment manufacturer was experiencing high product costs and delivery cycle times exceeding customer expectations. Approach Used Flow consultants implemented comprehensive leadership driven "Lean Enterprise" principles and a series of kaizen sessions with both exempt and hourly personnel. Results The company achieved:
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A 27 percent … [Read more...]
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