CASE STUDIES

RAPID CHRONIC PROBLEM IDENTIFICATION AND ELIMINATION

CONTEXT:  3rd Party Manufacturer with Significant Metal Contamination

                     Issue.  Five (5) defects found by consumers ($100 MM business                                     threat).

 

ACTION:     Led Focused Improvement effort across two sites to eliminate                                       the issue.

 

RESULTS:   Metal Contamination issue resolved in 10 days; the last report was no 

                    recurrences 48 months after intervention. 

ORGANIZATION BREAKTHROUGH IMPROVEMENT

CONTEXT:  Non-Profit Organization Annual Contribution report accuracy of                                     70% (30% error). 

ACTION:     Led Lean Six Sigma Team effort to improve accuracy to 85% (10%                                 improvement and reduce reconciliation effort by 20%. 

RESULTS:   Annual Contribution report accuracy improved to 90% (30%                                             Improvement)​

ENTERPRISE BREAKTHROUGH IMPROVEMENT

CONTEXT:   $10B Business Global Innovation Process was negatively impacting                              business growth due to extended implementation cycle (8 months)                              that resulted in 200 Innovation Master Plan changes per year.  Also,

                      over 300+ persons were involved in executing the process.

 

ACTION:      Aligned Group President and Leadership Team on the need for                                      improvement and led the Work Process Improvement effort.

 

RESULTS:     60% Cycle Time reduction, 90% Effort reduction, and 75%                                                Masterplan Stability Improvement.

STRATEGIC MASTER PLAN DEVELOPMENT AND IMPLEMENTATION

CONTEXT:    $300 MM Business had a compelling need to reduce COGS by 20%                                and improve operational and manufacturing capability.

ACTION:       Created and led North America "Virtual Juice Plan" - 3 independent                               plants and 1 operating module in multiple locations with an                                           integrated Strategic Master Plan.

RESULTS:     25% ($64 MM) reduction in COGS in 24 months; while improving                                  key performance indicators (Safety, Quality, Customer Service) by an                            average of 50%.