Archives: Case Studies

Shipping

Door Cell: Kaizen Rapid Execution

Problem: The Class 8 Semi Truck manufacturer was experiencing waste, rework, high inventory levels and missed shipping schedule requirements. This was creating excessive overtime, expensive expedites and cost over runs. Solution Eliminate overtime, waste, rework, expedites and re-engineer door cell to JIT pull system of production. Engaged Door Cell workforce to execute a Kaizen Rapid …

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Aerospace Suppliers

Problem: As the global inventory of aerospace grade titanium raw material inventory shrinks, the costs of processing titanium is increasing. Without addressing the costs of processing these parts our profit margins will decrease and threaten the finical stability of our organization. As the global inventory of aerospace grade titanium raw material inventory shrinks, the costs …

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Commercial Builders

Commercial Construction Builders: Kaizen Rapid Execution

Problem: The current accounting process has slowed and increased workload with a new banking regulation for increased scrutiny on the horizon, Commercial Builders required a new efficient and effective accounting system.  Solution Develop an E2E operational assessment and implement Kaizen Rapid Execution. Results 67% reduction in E2E accounting processes; 151 STEPS to 51 steps  Total …

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Medical Center

Medical Center

Problem: Labor, Delivery, Recovery, Post (LDRP) – 2mm in incorrect billing / coding, loss revenues, MSA 70 personnel 50% – 95% to standard Issue; 70 enterprise wide LDRP nurses and staff at 7 regional hospitals were using incorrect billing codes during the patient LDRP procedures within the Medical Center. This was resulting in a $4,000,000 …

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Generic Semi Trucks At A Parking Lot

Class 8 Semi Truck Manufacturer

Problem: The Class 8 Semi Truck Air Conditioning Line was experiencing excess waste and rework of finished goods, excessive redundant motion of workforce, and high inventory holing cost with low turnaround. Solution Execute Kaizen Rapid Execution Event. Redesign of the production push system to a TPS JIT pull system. Reduce waste, low inventory holdings, and …

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Build Bank

Washington Mutual

Problem: In 2008 Washington Mutual was the biggest housing thrift loan originator in the United States with over 2080 Financial Centers across the country. In addition to offering home loans to customers, WAMU also held consumer automobile, credit card, line of credit, equity, business and personal loans. The issue; consumers were able to walk into …

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