Manufacturing Improvements for a $130M Building Products Manufacturer

"An organization built by acquisition and continued siloed organizations led to a bloated facility footprint across a global organization"

The client was a $130M manufacturer of building product windows and doors
The company had purchased a new facility from a sole proprietor and recognized the need for investment
The organization was in the midst of updating manufacturing equipment and had experienced significant delays
High turnover had led to an increasing number of quality defects as well as diminishing output
Manufacturing outputs had begun to stress customer relationships and the site’s local market share had fallen from a peak of 70% to 40% in a period of five quarters

SLKone was engaged to review the in-process manufacturing line improvement project and add Project Management rigor
Reporting of manufacturing results was institutionalized, with data gathering, visual performance boards, and a review process with the manufacturing team was implemented
Unit flow analysis was performed to identify key bottlenecks and re-establish order release to prevent WIP build up

Increased overall facility output within a 3 month period from 800 windows and 150 doors to 1,100 windows and 250 doors (with additional growth capacity)
Installed control points and established a quality organization resulting in scrap reduction by over $100k per month
Reduced order lead times by 40% (2 days from 5 days) through process controls and inventory management processes
Reduced WIP inventory by 40% by controlling processes, establishing min/max levels, and implementing Lean concepts

Case studies and expertise may represent projects and engagements performed by SLKone team members prior to their employment at SLKone