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Collier & Associates brand mark featuring the core services: Business Transformation; Enterprise Systems; AI-Enabled Execution.

Global Industrial Manufacturing Firm (Multiple Divisions)

Client Challenge

A major industrial manufacturer had been unprofitable for over 20 years, due to outdated systems, fragmented operations, and poor cost visibility.

  • Leadership lacked timely, trustworthy data and couldn't measure the cost or profitability of products and customer segments.

  • Critical manufacturing process concepts weren't well understood, the organization lacked clear structure, and there were no integrated systems to support operations The company needed an end-to-end operational and financial transformation to return to profitability.

Client Solution

Deployed the BAS™ Value Creation Engine Solution for future-state process design

  • Conducted full operational and financial diagnostics using Lean methods and current-state cost modeling

  • Conducted Executive All-day Kaizen Sessions Designed and implemented an integrated JD Edwards ERP environment.

  • Trained all personnel in cost accounting, product configuration, and standardized reporting. Integrated shop floor data capture to improve throughput and quality control.

Client Impact Results

  • Financial Transformation: Improved EBITDA 30% in less than two years

  • Quality Revolution: Reduced shop floor mistakes and rework by over 75% within the first year

  • Work-Life Balance: Shop personnel took holidays during busy season for the first time in 20 years

  • Manufacturing Excellence: Reduced manufacturing cycle times from 8+ months to under 3 months.

  • Supply Chain Optimization: Reduced global sourcing of forged steel components from 18+ months to under 4 months, enabling millions in additional customer jobs

  • Operational Efficiency: 

      Reduced job estimating from weeks to less than 4 hours with increased accuracy

      Decreased project status reporting lead-time from 1+ week (with <50% accuracy) to under 1 day (with >98% accuracy)

      Eliminated time-consuming daily planning meetings attended by all Directors, Managers, and Supervisors

Client Technologies

  • JD Edwards ERP (JDE World 7.3)

  • SQL-based reporting tools

  • Business process modeling software

  • Shop floor data collection modules

  • Oracle database integration

  • Microsoft Project Server integration

Before working with Andy Collier there weren’t clear operating philosophies or an integrated system available to support them. Critical manufacturing processes concepts weren’t well understood, and the organization was loosely defined. Andy led the design of the system, actively helped with the cultural change, educated many key individuals on manufacturing and system concepts, and led the effort of testing and implementing our new system. Especially noteworthy is how savvy Andy was in accomplishing this while not being a direct employee or theoretically having any authority. Andy is the best business and IT consultant I’ve ever met.

Jeff Allen, VP ~ Alstom Power – Power Services Division (A Global 500 Company)

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