[email protected]
Operations center showing quality metrics and performance dashboards
Proven Results

Real Results. Proven Methodology.

Every engagement delivers measurable improvements. Here are examples of how our Fortune 500-experienced executives have transformed operations across aerospace, automotive, defense, medical devices, and industrial manufacturing.

0+
Implementations
0%
Certification Rate
ZERO
Non-Conformances
0%
Avg. Defect Reduction
Consumer Electronics / Automotive case study
Consumer Electronics / Automotive12 Months

$100M Greenfield Plant Startup — Delivered 2 Months Early

A Fortune 500 global manufacturer needed a new $100M production facility to meet demand that had surged 44% above forecast. We managed the supply chain planning, lean enterprise design, and launch execution — delivering milestones 2 months ahead of schedule.

$100M
Capital Investment
2 Months
Ahead of Schedule
$35M
Equipment Expansion
Read Full Case Study
Heavy Machinery / OEM case study
Heavy Machinery / OEM18 Months

Facility-Wide Kanban & Inventory Transformation — $1.7M Saved

A global OEM machinery manufacturer with 43,000 SKUs across 442 suppliers was hemorrhaging money — assembly lines shutting down from missing parts despite excess inventory everywhere. We implemented facility-wide kanban, PFEP, and visual management systems that tripled inventory turns and saved $1.7M annually.

$1.7M
Annual Savings
9→25
Inventory Turns
26%
Supply Base Reduced
Read Full Case Study
Automotive Plastics case study
Automotive Plastics12 Months

Lean Plant Redesign — 40 Trailers of Hidden Inventory to 100% OTD

A Tier 1 automotive plastics manufacturer was hiding suspect inventory in 40 trailers behind the plant while running 82% OTD and spending $52K/month on expedited freight. A value stream transformation recovered $375K in hidden inventory, eliminated external trucking costs, and drove OTD to 100%.

82%→100%
OTD Improvement
$650K+
Annual Savings
$375K
Hidden Inventory Recovered
Read Full Case Study
Heavy Truck Manufacturing case study
Heavy Truck Manufacturing12 Months

90-Day OTD Turnaround — 58% to 97% with 516-Piece Backlog Eliminated

A Tier 1 heavy truck wheel manufacturer was at 58% OTD with customers threatening to pull business. A 516-piece backlog for a major OEM was growing daily. In 90 days, we drove OTD to 97%, eliminated the backlog, and generated $2.6M+ in savings.

58%→97%
OTD Turnaround
90 Days
Turnaround Time
516 Pieces
Backlog Eliminated
Read Full Case Study
Heavy Machinery / Aerial Platforms case study
Heavy Machinery / Aerial Platforms5 Months

Cross-Country Product Line Relocation — 7,900 Components Resourced in 5 Months

A global OEM manufacturer needed an entire aerial platform product line relocated from Washington State to South Carolina — 7,900 components resourced, 10 kaizen events, and compressed from 8 months to 5. The first unit came off the new line on plan.

7,900
Components Resourced
8→5 Mo
Timeline Compression
10
Kaizen Events
Read Full Case Study
Defense / Aerospace case study
Defense / Aerospace18 Months

Defense Supply Chain Transformation — 50% to 97% OTD, DCMA Auditors Cleared

A mid-size defense manufacturer had 3 DCMA government quality representatives living in the facility due to chronic late deliveries. A corrupt buyer was steering POs to 4 favored suppliers. We rebuilt the entire supply chain — OTD went from under 50% to 97%, backlog went to zero, and the DCMA auditors left.

<50%→97%
OTD Turnaround
$425K+
Annual Savings
67%
Indirect Cost Reduction
Read Full Case Study

What Our Clients Say

We were turning away revenue every week because we physically could not make enough product. The new plant launched ahead of schedule with lean systems already in place — no ramp-up chaos, no re-learning. That is what program management looks like.

VP of Operations
Fortune 500 Global Manufacturer

When he arrived, we had 200+ parts short every day and assembly lines sitting idle with millions of dollars of inventory on the floor. Within months, the shortage list was down to 10 parts — and those were all new product introduction items. The transformation was visible to everyone who walked the floor.

VP of Supply Chain
Global OEM Machinery Manufacturer

He walked in and found 40 trailers of hidden inventory that previous management had been sweeping under the rug. Within a year, those trailers were gone, OTD was at 100%, and we were shipping on our own trucks instead of paying airlines to move our parts.

Plant General Manager
Tier 1 Automotive Plastics Manufacturer

We were 90 days away from losing our biggest customers. The war room went up on day one, and within 3 months our OTD went from 58% to 97%. The chroming supplier added a shift because he understood our situation — that kind of collaboration does not happen without someone who knows how to build real supplier relationships.

VP of Operations
Tier 1 Heavy Truck Manufacturer

Relocating an entire product line across the country in 5 months while launching 3 new products and implementing a new ERP — most people would say that is impossible. The first unit came off our new line right on plan.

General Manager
Global OEM Machinery Manufacturer

We had three government auditors living in our plant — that is how bad it was. He terminated a corrupt buyer, rebuilt our supply chain from scratch, and delivered 97 units that cleared our entire backlog. The DCMA representatives walked in one day, asked what happened, and left. They never came back.

President
Mid-Size Defense Manufacturer

Want Results Like These?

Schedule a consultation and let our executives assess how we can transform your operations.

Explore Services