Supply Chain Acceleration Case Studies

Supply Chain Rationalization process

Led initiative for a major pharmaceutical company to look at off-shoring non-critical assets in their supply chain. Recommendations led to significant cost-savings over the existing overhead model.

Manufacturing Footprint Project

Created a "Clean Sheet" analysis of a company’s ($2.2 billion) total supply chain and developed individual restructuring activities/plans in order to rationalize the manufacturing footprint.  The first year identified savings exceeded $70 million.

Lean Manufacturing Implementation

Implemented a Lean Manufacturing System based on elements of the Toyota Production System; Results: 15% reduction in WIP, 75% reduction in First Run Capability and 27% reduction in customer PPM.

Product Line Combination

Merged two product lines in order to reduce indirect costs and improve capacity utilization; Results: avoided $1.2 million of capital expenditures and saved $650K annually.

Implemented Continuous Flow Manufacturing (CFM)

Established Max Queue’s, Trigger systems, KanBans and visual indicators of production attainment. Results included reduced cycle time of three days and inventory reduction of $6 million.