Lean transformation adding $8.2M for a transport systems firm
- Location
- Indiana, USA
- Year
- 2023
- Engagement
- Profitability Improvement: Operations Productivity
Leading manufacturer of truck bodies looking to streamline production for reduced costs and better customer service. Anticipated significant market correction and required external support to prepare for tighter margin, low volume. Requested an end-to-end diagnostic (order to delivery).
Our team conducted various studies across five plants in sales, identifying key issues: 1) Orders were over-customized causing no standardization; 2) Incomplete engineering and late changes left unusable product resulting in delays; 3) Materials not synced with production planning.
Measurable impact
9 mo
Completed a 9-month overhaul of the truck bodies business including process and system changes across five plants
Automotive, Watercraft and Powersports
Measurable impact
$25M
Estimated $20-25M annual savings on $400M revenue
Automotive, Watercraft and Powersports
Case snapshot
Additional phases conducted to leverage new operating model for additional savings opportunity
Automotive, Watercraft and Powersports