Case Study Examples

Rapid Improvement Workshop to relocate production line 

• 30% less space required
• 70% less work in process
• 62% less distance travelled
• 40% lead time reduction
• 34% increase in productivity

• Strategy Deployment Workshop
• Value Streams Identified
• 15 rapid improvement workshops completed
• Overall productivity increased by 20%
• cost of inventory reduced by 64%
• Cost of quality reduced by 18%
• 22% positive impact to the bottom line

• Problem: Losing business due to lead times of more than 28 days.
• Target : 5 day lead time
• Solution: A series of workshops to reduce variation and increase flow
• Lead time reduction of 82% achieving 5 day lead time
• Reduced In Process Inventory by 80%
• Increased productivity by 40%
• New service level allowed company to increase prices

Before:

• 120 days to close complaint
• After:
• reduced handoff by 66%
• standard team meeting developed
• investigation and root cause process scripted into the work day
• Visual tracking of complaints
• average time to close complaint 4 days (95% reduction in response time)

Situation:

• Enclosure assembly identified as a bottleneck impacting final assembly process.

Target:

Balance enclosure assembly to final assembly Takt Time

Action:

• Break Through Kaizen

Results:

• reduced work content by 37%
• reduced lead time by 83%
• Enclosure assembly balanced to final assembly