For
a major metals smelter/converter implementing Lean as a common Manufacturing methodology with in-house personnel
provided Trusted Advisor services, including coaching, expanding on training materials based on experience and focusing on
the client's successful Enterprise roll-out at reasonable cost.
For
a major North American freight line suffering from poor workforce planning and a lack of responsiveness to
daily operating differences, increased labor productivity by 35%, significantly reduced freight damage claims/late delivery
charges and higher truck utilization allowed reduction in fleet.
For a significant Power Generator manufacturer
with severely eroding margins, increased overall throughput by 40%, increased output by 12%, produced a 15% increase in palletizing
unit output and eliminated 2 shifts while maintaining previous throughput levels.
For a major Technology
Services supplier with eroding Margins, increased overall productivity by 40%, reduced overtime costs by 45%,
eliminated 35% of the spare parts inventory, cut 65% of overnight parts shipping costs and reduced customer contract specified
performance penalties by over 50%.
For a significant Tier 1 Communications company with confusing pricing
models, product bundles not aligned to customer needs and an underachieving sales force, achieved a 22% increase in cash flow,
turned around sales plan achievement to overachieving the forecasts by an average of 15% and grew add-on service revenues
by 100%.
To support a leading B2B portal's need for sustained growth, achieved
IT alignment, implemented a new product strategy and Product Roadmap process. Reduced Operational Costs by 4X fees.
For the largest global aerospace and defense company, created and delivered a comprehensive
Lean Change Manager program that included Leadership Skills Training, Change Management Principles, Lean Training and Tools,
Implementation Skills and Continuous Improvement/Kaizen Event Facilitation; trained and certified 45 Lean Change Managers
who performed over 60 Kaizen events, with our mentoring, realizing over $100 million in savings; reduced average cycle times
by 30%.
For one of the largest food service, bakery, and food and beverage suppliers in the
world, led the project that trained 60 Lean leaders in Lean Office Kaizen that performed, with our mentoring,
over 50 Kaizen events resulting in savings and top line revenue improvement over $48 million and $15 million the first year.
Created, delivered and transferred to client Lean Leadership training programs for 10,000 executives, managers and talent
level staff.
For the largest computer manufacturer in the world, managed a major
supply chain optimization project that helped install a new worldwide distribution model; facilitated the senior leadership
team's weekly global initiative meetings; coached and counseled the entire leadership team. Built a new build to order factory
in 6 months; improved outbound distribution by 50%; helped install new distribution model which changed production from build
to forecast to build to order; reduced distributors inventory from an average of 12 weeks to 2 weeks, saving over $500 million.
For a large aerospace
defense contractor, in response to a poor DOD audit, worked with Manufacturing Management to change the build
methodology from fixing errors detected during final QC of a finished plane to passing intensive workstation/bay specific
QC before promotion to the next production step. Implemented a bottoms-up dashboard to show the build and QC status by hull
number throughout production stages. Result was both cost savings and a favorable response by the DOD auditors.