Need to increase throughput in an operation at capacity with on time delivery of 21.7%
Operations Deep Dive used to prioritize changes in the workflow to streamline, create capacity, and improve output
$3.1M in incremental revenue created. 80%+ on time delivery in 60 days with a 8.5% throughput lift.
Excessive cash tied up in inventory. Needed to increase inventory turns, without impacting customer order fill rates.
Inventory Deep Dive identified 53% of the inventory was stuck in work in process, and 87% of the finished goods SKU's sold less than 25 pieces per month,
$900k in working capital identified and action plan put in place. Additional $350k of working capital realized by moving to smaller lot sizes.
Borrowing limits were reached. Softening of orders and growing inventory choked cash flow.
S&OP Deep Dive determined no formal communications loop existed between Sales & Operations. As a result, purchasing was buying more than sales was selling.
$6.93 million in cash created in nine months. 41% reduction in inventory, closed offsite warehouse. Aligned purchasing with true sales demand.