Direct to Consumer bespoke Framing business had difficulty scaling operations to meet increased demand after transitioning from a VC backed company to a division of a publicly traded company. Through the stand-up of three new facilities employing single-piece flow, sound manufacturing techniques and ERP system upgrades, capacity significantly increased and resulted in an 80% improvement to OTD, a 60 % reduction in lead times, and a 33% increase in Quality at lower manufacturing costs. Total project savings of $2.5MM.

$350MM family-owned Window treatments business had many inefficient facilities, huge inventories and output problems. Lead times were greater than 4 weeks when the Market expected 2 weeks or less for custom-made products. Through consolidation and streamlining activities, Strategic Sourcing and SIOP actions, lead times were reduced by 75% and inventory by 27%, OTD improved 57% and Quality 148%. Total project savings of $9.8MM.

A $500MM, Private Equity owned, Thrift store with 18 processing facilities maintained low Operating Margins and very high recordable injury rates required revamping. Through deployment of Operational Restructuring and Lean Six Sigma techniques, Operating Margins improved by 11% and Safety 82%. Indirect costs were reduced by 15 % as part of the restructuring.