Recent Results

Global Machined Products Manufacturer

Issue: Too many warehouses, ever increasing distribution costs
Solution: Optimizing the current manufacturing and distribution network showed significant savings by relocating product lines and consolidating manufacturing and distribution footprint. A 2 DC solution was selected from 30 potential North American DC sites for parts distribution and imported finished goods.

Industrial Components Distributor

Issue: High inventory
Solution: Used six sigma tools to identify that 40% of the inventory in the distribution center was obsolete
Results: Converted 70% of the dead inventory into cash through sales

Automotive Processing Center

Issue: Desire to delay needed expansion
Solution: Used lean flow and inventory management techniques
Results: Reduced manufacturing capacity utilization from 97% to 61% in 12 months, delaying a $25M investment by 7 years

Paper Industry Supplier

Issue: Cash flow constraint
Solution: Used lean sigma techniques in their accounts payable process
Results: Increased cash flow by $186K/month

Automotive Parts Distributor

Issue: Warehouse storage capacity
Solution: Statistical safety stock to improve both inventory turns and order fill
Results: Reduced distribution center storage capacity utilization from 96% to 81% in 6 months, delaying a $30M investment by 5 years

Industrial Supplies Distributor

Issue: Slow moving raw material inventory
Solution: Implemented integrated commodity team management techniques and multi echelon inventory planning
Results: Improve total supply chain inventory turns from <4 to >6 on $100M

Plumbing Supplies Distributor

Issue: Acquisition integration, increased sales, need for quicker delivery
Solution: Design distribution racking layout and product slotting optimization
Results: Lower shipping and warehousing cost with improved delivery lead time