TriVista Delivers $1.7M EBITDA Savings Through Productivity Improvements

A $150M private equity backed building products company.

The Challenge

• Our client experienced high turnover during the past three years while growing revenue 30% during the same period
• TriVista was retained to improve overall operational and labor efficiency across multiple work sites
• The assessment was immediately followed by support

Our Approach

The TriVista team used the Define, Measure, Analyze, Improve, and Control (DMAIC) problem solving approach to clearly identify improvement areas, quick win projects, and longer-term cost savings opportunities:

• Delivered a series of Kaizen events aligned with labor reduction in key work centers
• Balanced work activity with customer Takt time to increase overall labor utilization
• Developed subassembly cells to drive one-piece flow to the main assembly lines
• Created visual work centers and Quality, Delivery, Inventory, and Productivity (QDIP) boards to improve shop level communication
• Deployed work instructions to standardize job activity, simplifying training, and onboarding
• Used advanced statistical tools to validate operational improvements

The Results

• Reduced direct labor by 24% across 6 work centers during Phase 1. The client confirmed $1.4M in annualized EBITDA savings
• Based on assessment results, the client retained TriVista to complete a second work stream
• Further reduced direct labor by $300K during implementation phase
• Completed the Manufacturing Management System (MMS) deployment and transitioned ongoing continuous improvement activity to the internal Continuous Improvement (CI) Group