A Sampling of Client Results
Bal Seal Engineering Company
- Doubled net profit
- Reduced inventory 50%
- Eliminated overtime
Boeing's Printed Circuit Board Center
- Reduced scrap by 90%
- Reduced lead-times by 75%
- Increased output by 75%
CAE USA
formerly Reflectone, then BAE Systems Flight Simulation & Training
- Reduced cycle times by 2-4 months (and improving)
- $37 million increase in the number of profitable programs
- Saved more than $4 million in the first year alone
- Avoided doubling manufacturing staff (70-140)
- Reduced per project carrying costs by $400K
- Recovered major customer - additional $12 million contract
CM Products
- Decreased finished goods inventory by $400,000
- Reduced operating expenses by $900,000
Corning Display Technologies
- Reduced inventory by 60%
- Increased sales volume by 10%
- See their story. (03:31)
Cryovac
- Decreased inventory by an average of 5-15%
- Distributors achieved 5-20% increase in sales
F22 Project Raptor: Boeing and Lockheed Martin
- Boeing
Unprecedented performance - on schedule, under budget. Reduced required wing assembly time by 50% - Lockheed Martin
Cut final aircraft full finishes time by 57%, without reducing scope
GM Powertrain
- British engine plant increased production by 36%
- Metal casting system uptime increased 25% (and still improving)
- Transmission case machining uptime increased by 40%
Gunze - Apparel & Hosiery Division
- Reduced WIP >40% in nine months (Apparel) and >15% in 13 months (Hosiery)
- Decreased lead-times by four days in both divisions
- Reduced 'out-of-stock' by >50% (Apparel), >70% (Hosiery)
- Reduced customer returns by >50%
Gunze - ELMA (Electronics Division)
- Achieved planned results more than two years ahead of schedule
- Reduced lead-times (three plants combined) from 21 to four days
- Reduced inventory by 80%
- Improved due date performance by 12%
Harris Semiconductor
- Grew by 40% when industry standard was 10-20%
- Plant improved from zero profit to generate 80% of division's & 20% of company's profit
- Increased from two to seven cycle turns per year (industry standard was four)
- Constructed new manufacturing facility and began high-tech full production in 13 months, instead of 54-month standard
Israeli Air Force
- Reduced F-16 airframe and structure upgrade time from eight to five months, saved $5 million
- Supply chain parts distribution improved 28% at no additional cost
- Reduced wait time at electronics depot bottleneck from three months to two-to-three weeks
ITT Industries Night Vision
- Successfully applied TOC to open new commercial market when previous experience was only military sales
- Doubled sales in three years
Lucent Technologies
Benefits achieved with no increase in resources:
- More than tripled development project capacity (5 to 17)
- Reduced new product introduction intervals by 50%
- 100% of projects completed ahead of schedule
- Improved revenue by 30% - multi-million dollar profit improvement
National University Hospital - Singapore
- Improved patient admission times by more than 50% (from 6-8 hour average to <3 hours); 63% of patients are admitted in less than 1.5 hours
Nike
- Reduced warehouse inventory by 20%
- Increased gross margin by $300,000
- Achieved 40% increase in sales during peak season
- Within four months, inventory turns went from 2.3 to 7.0
- Reduced warehousing costs by over $2 million per year
- See their story. (02:46)
Oregon Freeze Dry
- In four months, reduced finished goods inventory by 21%
- Increased on-time deliveries from 97% to 100%
- Reduced 'make-to-order' lead times by more than 50%
Pratt & Whitney
- Completed additional three months work without expediting or increasing costs
- Completed three of four projects on schedule and under budget; fourth project failed to respect TOC-planned task dependencies and suffered delay and budget overrun
- Employee survey showed improved task focus and reduced multitasking in only five months
- Completed 45% of tasks in less than half of originally projected task durations
Republic Industries
- Reduced late deliveries from 60 to 20
- Achieved nearly 20% growth in sales
- See their story. (02:46)
- Republic on Throughput Accounting (01:39)
- Republic on ANALYZE and MANAGE (02:35)
Seagate Technology
- Launched high-tech product five weeks ahead of schedule
- Generated additional incremental revenue of $11 million with $5 million in additional profit
TIMCO Aviation Services
- Improved on-time aircraft deliveries from 44% to 77%
- Reduced number of service days required by 8%
US Naval Aviation Enterprise AIRSpeed (US Navy & Marine Corps)
- Sustained $340 million cost avoidance in engine inventory
Pacific Region Site (Hawaii, USA)
- Decreased by 66% required inventory of engines
- Reduced by 24% replenish time for main tires
- Saved $1.25 million in first year
South-West Region Site (California, USA)
- Reduced engine repair times: 78 days to 8 days
- Decreased component lead times by 33% for airframes & 15% for avionics
- Eliminated more than 5,300 overtime hours/year (overtime was the norm for 7+ years)
Mid-Atlantic Region Site (Virginia, USA)
- Reduced repair times in 90% of work-centers
- Achieved $1.3 million in actual savings
- Identified $5.1 million additional savings
Overseas Operations Site (Iraq)
- Improved aircraft-on-ground (AOG) supply chain effectiveness to forward sites from 45% to 98%