Case Studies

Results from the floor, not the whiteboard.

Every case study follows the same structure: the challenge as it actually presented, the diagnosis (what the data revealed), the lean intervention, and the measured results — with the numbers that appeared on the client's P&L.

Automotive14 weeks

From 47-Minute Changeovers to 9: SMED Transformation at a Tier-1 Supplier

A Tier-1 die-casting supplier was losing nearly 2,800 production hours per year to slow changeovers and unplanned stoppages. Fourteen weeks of focused SMED work and TPM foundations transformed a chronic underperformer into the plant's highest-OEE asset.

Food & Beverage18 weeks

Cutting Lead Time from 8 Days to 38 Hours in a High-Mix Snack Facility

A regional snack foods manufacturer was drowning in WIP inventory and missing customer windows. An 18-week lean transformation — anchored in value-stream mapping and a supermarket pull system — reduced lead time by 80% and freed $1.7M in working capital.

Floor Space Reclaimed

Value-Stream MappingPull SystemsInventory ReductionFood & Beverage

Aerospace22 weeks

From 4.2% to 0.8% Scrap: Poka-Yoke and SPC in Aerospace Components

A machined-components supplier to a major aerospace OEM was generating 4.2% scrap on tight-tolerance titanium parts — costing $2.1M per year and generating quality escapes that threatened the customer relationship. Twenty-two weeks of A3 problem-solving and poka-yoke engineering reduced the scrap rate to 0.8%.

Poka-YokeSPCQualityAerospaceA3

Medical Devices16 weeks

18% Throughput Gain at a Medical Device Assembly Facility

A Class II medical device assembler was running two shifts at full headcount but still missing customer delivery commitments. By redesigning the assembly cell around takt time and standard work, KAIZEN unlocked 18% more throughput — without adding a single operator.

Medical DevicesStandard WorkTakt TimeThroughput5S

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