1Challenge
Disparate systems from the acquisitions hid the business's true capacity. Asset use, throughput, setup time and scrap all needed work.
2Approach
- Found hidden capacity and built a financial roadmap for which plants to consolidate and which to improve
- Ran a weekly critical-path review with 200+ action items, loading profiles and a safety-stock plan
- Installed a closed-loop MOS on four fronts in 12–15 weeks, with changeover teams at each site
3Results
~$36M
Value created
$6M
Annualized cost savings
16%
Productivity improvement
22%
Scrap reduction
Five plants became four, lifting EBITDA without disrupting major customers.
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