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Lean Manufacturing Consultants

• Established effective lean organizations at staff and plant levels

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• Implemented cross manufacturing for components within different businesses to realize significant savings

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• Authored a next generation product road for a consumer durables company

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• Worked with a company to create a US made product that was competitive with China and featured in WalMart's "Made in USA" program

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• Recovered 90% of lost schedule and $1.0M in overruns on a $10M product initiative.

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• Worked with an industrial controls company to standardize their product offering across several different platforms

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• Worked with Mexican, Far Eastern, European and US Operations introducing Kaizen and standardized push/pull inventory improving productivity over 20%

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• Project managed greenfield sites to manufacture bicycles, turbine engines, hand tools and houseware products.

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• Relocated manufacturing operations in Europe, Southeast Asia, North America and Eastern Europe for faster supply chain response, resulting in 50% landed cost reductions

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• Implemented several reengineering projects and new product programs in the irrigation industry

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• Restructured six manufacturing and six distribution facilities resulting in $250mm in cost reductions.

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• Drove 10 years of cost inflation out of a Mexico produced product

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• Introduced 'Kaizen' lean manufacturing improvement processes at a consumer durable factory, reducing labor cost $850K, improving finished product quality by 50% and creating 23K square feet of manufacturing space for needed manufacturing expansion.

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• Implemented a lean manufacturing approach to an industrial product’s operation, allowing for management and consolidation of an aged New England plant. The consolidation and relocation of operations to North Carolina was completed without creating market or cost disruptions. Eliminated redundant costs of $1.7M.

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• Developed 'just in time' delivery process to increase service levels to +98% on an expanded industrial products business (over 3000 SKU's) by developing strategic kanban inventory and fast turnaround manufacturing processes.

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• Implemented lean manufacturing processes at two different SE Asian manufacturing operations, achieving 15 – 20% yearly improvements in labor, and more than 5% annual cost savings.

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• Created equipment monitoring system for manufacturing plant. System monitored machine ‘on’ time as well as activity. This information was compared with daily production numbers, determining machine efficiency. Information also allowed for better directed equipment maintenance and upkeep.

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• Created and implemented large inventory process and database for contract manufacturer. Nature of business required continuously changing space utilization to be able to handle production swings. Both the method of storing and database for monitoring were replaced. System increased effective use of warehouse space by 90% while improving speed of truck loading/unloading and nearly eliminating mis-shipments.

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• Redesigned corporate phone/ fax/ data handling system. System included all hardware and new database software – built to incorporate existing system functionality. System resulted in an unintended complete overhaul of client’s personnel job functions and methods. Package cost in excess of $250,000 and required a full year to completely design and implement. Resulted in staff reductions of more than 60% with a cost savings of over $1.6mm per year. Support staff was reduced from 108 to 32 people.

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