Case Study

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"

Situation

  • 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

Bespoke Solutions

  • 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

Leading With Results

  • 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
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