Industry · 05 / 06 · saved $31M
The hero retired
A global operator whose plants only hit plan when three people stayed on the floor. We installed the night system. $31M recovered. Name withheld.
The problem
The hero retired
A global operator’s plants only hit plan when three people stayed on the floor. Vacations were a risk event. Scrap and overtime were the tax the board had learned to live with.
How we resolved it
$31M
saved
We installed the operating system the floor could run at 2 a.m. Throughput held. Scrap fell. The Tuesday hero is unemployed — and the plan still clears.
If we are not there
$40M / yr
still goes
If we are not there, the plants only hit plan when three people stay on the floor. Scrap and overtime remain the tax — about $40M a year still goes. Vacations stay a risk event.
Next engagement
Price without apologyMaison · saved $9M · if absent $12M / yr