$3 million reduction in required capital

System integration cost-savings of 60%

11.9% reduction in cost per unit output, and a 193.2% ROI

12.4% reduction in Manufacturing Added Costs, a 20.8% decrease in consumer complaints

15% improvement in efficiency and a 20% reduction in waste

28% mill waste reduction, 50% improvement in asset utilization

 

Brief portfolio of our past accomplishments

• Delivered System Integration cost-savings of 60% compared to the closest market alternative on a series of packaging lines for a major Pharmaceutical Manufacturer. We simplified the approach and eliminated non-value-add services that were bundled into the larger integration firm offers and utilized available client resources whenever possible.


• Provided Owner's Representation for a $43 million capital expenditure for a major Pharmaceutical Manufacturer. Roles included conceptual development, process engineering and modeling, bid package development for solution providers as well as bid review.


• Provided new product integration analyses for a major baked goods manufacturer. Primary role is to provide manufacturing network evaluation of capacity and capability in order to determine best fit scenarios for new product integration. When capacity or capability issues necessitate we continue to deliver system design change development and implementation.


• Delivered a Six Sigma data collection study for a snack foods division of a major food manufacturer that targeted waste reduction, throughput gains and labor utilization opportunities. The recommendations following the data event set off internal continuous improvement activities that delivered an immediate 10% gain in throughput combined with a 30% reduction in waste. It also began a focused transformation of the skills and systems of management from that of a labor-intense manufacturing environment to one of an automation-based environment.


• Identified hiring, training, equipment, and facility deficiencies causing significant limitations to the long-term viability of a nationally known beverage operation. A custom-designed recruiting, hiring, and on-boarding process integrated with a performance-based training program and coupled with an equipment upgrade plan was cited for achieving a turnaround in the operations. Results attributed to the intervention included an additional 1.2 MM cases produced, an 11.9% reduction in cost per case, and a 193.2% ROI.


• Designed and implemented a leadership skills development program for a private label manufacturing organization resulting in a 12.4% reduction in Manufacturing Added Costs, a 20.8% decrease in consumer complaints, and a 6.3% improvement in the organization's Safety Index.


• Developed, implemented and transferred a process control methodology to papermaking, tissue converting, and recycling operations in the UK. Performance improvements attributed to the methodology included 28% mill waste reduction, 50% improvement in asset utilization, and 81% machine efficiency. Methodology subsequently implemented in all of the company's factories in Sweden, France, Germany, and the Netherlands.