Multi-Site Manufacturing Company Grew 500% through Acquisition

The Challenge

Over a 3-year span our client expanded their operating footprint with the acquisition of 5 business with little integration. The rapid growth caused conflicting messaging across the enterprise and a siloed approach to core business functions including Sales, Product Development, Pricing, Engineering, Supply Chain, Scheduling and Manufacturing. The lack of synergy and adoption of best practices resulted in slower than expected growth, lost cross sell opportunities, and animosity between the individual businesses. TriVista was retained to create and deploy a consistent Operations System focused on one vision, enterprise leadership standards, and disciplined reliance to performance metrics.

Our Approach

• Identified a proof-of-concept product value stream with lower than planned margins, high growth and customer backlog, with low On Time, In Full delivery
  • Deployed on Operational System to solve performance issues
  • Used technical tools to improve material flow, layout and units per day output
  • Incorporated daily coaching, leader work standards and proactive problem solving to sustain improvements
• Elevated proof-of-concept work into a series of production centers-of-excellence across multiple facilities and high growth product value streams
  • Integrated Operating System tenets at each facility
  • Mirrored coaching, leader work and standards at each facility
  • Designed work cells across each value stream to improve unit throughput, balance labor and highlight process variation
• Targeted service levels improvements across the front end to include quote response times, pricing accuracy, and product add-on cross selling
  • Conducted a series of rapid improvement events to streamline pricing categories
  • Developed pricing playbooks to improve accuracy and timeliness
  • Created a transformation maturity scale to enable leadership to gauge adoption of new tools and a new way of working

The Results

• Achieved an 80% increase in weekly output and reduced labor 50% on proof-of-concept value stream
• Center-of-excellence highlights included;
  • 600% output improvement
  • Accelerated shipments on a $75M backlog to reduce delivery lead time by 50%
  • Reduced Front End quote processing times by 60% and improved overall win rate by 5%