From Chaos to Clarity: A Strategic Overhaul for $220M Success

PROBLEM: There was no strategic vision or tactical plan for reinvesting $220 million from the parent company into the site, which led to a delay in funding.

METHOD: Hoshin Kanri, Value Stream Mapping, FMEA, Six Sigma, Organizational Design, Lean Design

SOLUTION: A 5-year plan was developed to streamline the site’s operations to focus on core, profitable processes. This plan included reorganizing capital equipment from ten separate buildings into a single, efficient workflow that utilized distinct value streams.

Scaling Smarter: Building a Lean Foundation for 10x Growth

PROBLEM: The company experienced rapid growth, expanding its customer base through aggressive acquisition of processes and technologies. However, this expansion created a fragmented operational ecosystem with incompatible systems and inefficient workflows. The lack of integration resulted in operational silos, inconsistent customer experiences, and increased costs, while the company had the goal of expanding its customer base by 10x.

METHOD: Organizational Design, Hoshin Kanri, Lean Leadership, Daily Management, Practical Problem Solving, Gemba Walks, Standard Work, Leader Standard Work

SOLUTION: The company implemented a Lean Operating Model to streamline operations, integrate technologies, and establish a scalable foundation. This approach standardized and simplified workflows, eliminated inefficiencies, and aligned processes with customer needs. A dedicated Lean team led continuous improvement initiatives, supported by staff trained in Lean principles, to foster a culture of innovation and accountability. Technology systems were unified for seamless data flow with clear metrics, thus ensuring sustainable growth. This model enabled the company to start scaling efficiently while delivering consistent, high-quality customer experiences.