Every result below is tied to audited baselines with finance sign-off. No estimates, no projections — verified savings.
| Result | Detail | Impact |
|---|---|---|
| +25 OEE points | 50% → 75% across two lines | ~$1.1M/yr savings |
| 38% changeover reduction | 50 → 31 minutes via SMED | ~$343K/yr run-rate |
| 22% unplanned stops reduction | SAP analytics + operator coaching | Significant uptime gains |
| 19% scrap reduction | Poka-yoke implementation | ~$260K/yr savings |
| $495K annual labor savings | Kaizen + automation integration | Direct P&L impact |
| 25K meals/day ramp | Pre-Easter, zero overtime | Via takt design |
100-Day Methodology
Every engagement follows the same proven sequence: Stabilize, Lift, Lock.
Days 0–30: Stabilize
SQDC/LPA reset. Constraint mapping and OEE loss tree. Sanitation risk tiers. Skills-matrix baseline. SIOP gap audit. Establish baselines with finance.
Days 31–60: Lift
SMED implementation on the constraint. Top-5 downtime RCAs. FPY defect Pareto. Takt and crew balancing. QR-linked SOPs deployed to the floor.
Days 61–100: Lock
Playbooks and train-the-trainer. Power BI + SAP dashboards live. Replication to sister lines. Capital-lite roadmap for the next 12 months.
For detailed examples, see the Case Studies.