Turning Challenges into Opportunities
- Reducing Cost Across the Manufacturing Pipeline: Identifying waste, bottlenecks, and preventable downtime that inflated operating costs.
- Minimizing Unplanned Downtime: Moving away from reactive responses that disrupted production schedules and throughput.
- Accelerating Failure Learning and Response: Improving how quickly teams could detect issues, understand root causes, and prevent repeat events.
- Improving Inventory and Stocking Confidence: Enabling better coordination with vendors and maintaining optimal inventory levels across warehouses and stores.
Transformative Results
- $70 million in annual efficiency created within the supply chain, with benefits that carry forward year over year due to lasting operational improvements.
- Factory uptime exceeded “five nines” performance, achieving just 13 seconds of total downtime across the entire year.
- Mean time to learn from failures and address issues drastically improved, reducing repeat disruption risk.
- Reduced downtime exposure through a combination of proactive machine checks and a planned maintenance cadence.
- Meaningful gains in line efficiency and materials efficiency, supported by improved data and operational consistency.
- Stronger stocking outcomes through improved vendor coordination and more reliable inventory optimization across warehouses and stores.