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A major industrial manufacturer had been unprofitable for over 20 years, due to outdated systems, fragmented operations, and poor cost visibility.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