Case Studies

Proven execution.Built to perform.

Real operations. Real pressure. Measurable results. Every case below is an operation that had to execute and perform under conditions like yours. The proof is in what we built side by side with our clients. A resilient execution capability. And the lasting results it produced. Search by industry, service type, or operational challenge.

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Industrial Manufacturing

#01

Plastics manufacturer: scrap down 64%, quality findings down 60%, startup scores up 36% in 11 weeks

64% scrap reduction; 60% quality findings reduction; 36% startup score improvement; 6% run rate improvement; 18% setup reduction; 9% changeover time reduction

Proven execution.Built to perform.

Plastics manufacturer: scrap down 64%, quality findings down 60%, startup scores up 36% in 11 weeks

Wholesale Health Food Distributor: $1.25M saved, output up 7.4%, labor cost down 5.9%

Wholesale plant grower: 3.9-to-1 ROI, propagation up 65%, peak-week crews cut 11.5%

Midwestern turkey producer: $2M+ saved, load up 63%, overtime down 18%

Tier 1 Automotive Manufacturer: $1.2M saved, productivity up 30%, OTIF up 80%

Tier 1 metal supplier: changeover cut 50%, UPLH up 26%, 300+ ft travel gone

Global specialty pharma: 93% of products scheduled, rhythm wheel built in 5 weeks

Specialty pharma manufacturer: release time cut 46%, days in lab down 67%

Specialty baked goods manufacturer: productivity up 19%, losses down 28%, overtime down 21%

Special-Risk Accident Insurer: backlog down 70%, cost per claim down 30%

Snack manufacturer: productivity +16%, on-time +16%, changeover downtime -25%

Professional Safety Products Manufacturer: boxing up 34%, shipping up 52%, OTD up 36%

RTD beverage manufacturer: first-pass quality up 43%, 16 inspection points installed

Ready-to-eat meats processor: $70M recouped, labor cut 27-33%, downtime down 62%

Raw pet food manufacturer: $7M inventory freed, working capital cut 20%

Major QSR franchisee: 400+ leaders mobilized, 10 restaurants integrated, culture systematized

Puerto Rico distributor: receiving up 64%, picking up 35%, overtime down 16%

Protein manufacturer: $1.25M saved, give-away cut 17.8%, yield held

Major poultry producer: new plant to full ramp in 90 days, on plan

Large-Scale Poultry Processor: spend cut 39.5%, CMMS up 33.4%, PM up 22.6%

Poultry cold storage DC: $4.5M+ saved, productivity up 57%+, on-time shipping up 46%

Global potato processor: sanitation cut to 18 hrs, mechanic utilization 35% to 80%

Midwest pork processor: $10.8M saved, $6.5M yield recovered in 40 weeks

Plant-based meat manufacturer: capacity up 26% from 46%, OEE +14%, yield +2%

Pie shell manufacturer: 208% annualized ROI, labor efficiency up 50%, filling yield to 89%

Pet food manufacturer: $13.8M saved, capacity up to 68%, quality up 19%

Private Equity-Backed Industrial Manufacturer: 17% productivity, 2M lbs/year, 0 added staff

Packaging manufacturer: $1M+ saved, units per labor hour up 27%, labor cost down 18%

National food manufacturer: 11% labor productivity, 33% throughput, 10% cost cut

National Medical Supply Distributor: $2.4M saved, overtime cut 47%, labor down 9%

Medical and personal care manufacturer: labor cost cut 30%, startup up 50%

Global medical device manufacturer: $4.5M saved, 25% line gain, 15% more output

Global meat processing leader: on-time startups 52% to 91%, overtime cut 17%

Meat packing leader: $5.8M saved, ham yield 99% to 104%, 75-week slide reversed

Mass Retail Poultry Processor: $6M saved, yield up 6%, overtime cut 45%

Large manufacturing operation: $6.3M saved, labor productivity up 26.9%

Library and archival supply company: $2.1M saved, productivity +20%, service +35%

Library and archival supply company: MOS rebuilt, workstation output up 15-20%

Food and ingredients manufacturer: $42.2M saved, 620% ROI, no work cut

International automaker: stoppage 4.6% to 1.4%, OEE up to 103%, productivity +17%

Industrial Safety Products Manufacturer: boxing up 23%, shipping up 17%

Industrial Lumber and Packaging Supplier: $500K saved, labor down 12 pts, delivery at 100%

Major independent poultry producer: $30M turnaround, $4-5M saved at one plant

Home furnishings: 49% productivity gain, $2M+ saved, wages up

Hamburger Patty Processor: $1M saved, yield up 1%, productivity up 16%

Group insurance contracts: on-time up 60%, aged backlog down 62%, 3 years of growth absorbed

Global Nutrition Company: OEE 71% to 95%, $2.36M conversion cost cut

Global aluminum producer: $2.0M saved, throughput up 28%, sow quality up 60%

Frozen Food Manufacturer: $2.53M saved, MUV cut 73%, productivity up 41.8%

Major food processor: $6.1M annualized savings, verified by finance

Large-Scale Food Processor: uptime and reliability up 34%+ in three months

North American Food Manufacturer: zero safety incidents, zero quality escapes

Food manufacturer: $3.46M annualized, 6% performance gain, 12% less waste

Family meat processor: throughput up 47%, labor cost down 3.4%/lb, yield up 0.41%

Established food manufacturer: $4M+ saved, productivity up 19%, overtime cut 32%

Global renewable energy manufacturer: $1.2M added profit, overtime cut 50%

Global Dairy Producer: 41% productivity gain, rework cut 46%, 48,000 lbs/hr held

Northeastern dairy and coffee producer: $6.7M saved, packaging up 36.9%, line up 33.4%

Global consumer-goods manufacturer: throughput up 36%, OEE up 10%, uptime up 5%

Coated foods manufacturer: on-time 78% to 92%, 92% uptime, output up 9%

Major beverage manufacturer: 7% output gain, utilization recovered, accuracy 23% to 88%

Major Beef Processor: $2.3M saved, R&M cut 13%, planned work at 108%

Pre-cooked BBQ manufacturer: $2.2M projected savings, yield up 1.5%, OEE up 10%

Consumer baked goods producer: $3.4M OEE savings, Power Hour up 50%, OEE up 14%

Automotive Aftermarket Parts Manufacturer: 20% productivity gain, safer flow, room to scale

Animal Nutrition Supplier: 2.09:1 ROI, labor hours down 4.5%

Animal Nutrition Producer: scrap cut 65%, COPQ down 45%, temp labor down 15%

Global private agribusiness: 13 HR policies standardized, 10 core processes mapped

Global Agribusiness Manufacturer: throughput up 24%, uptime up 11%, startups up 73%

Home furnishings: 49% productivity gain, $2M+ saved, wages up

Defense manufacturer: 56% to 89% on-time performance