Manufacturing Optimization and Lean Implementation

Leveraging TriVista’s Lean Six Sigma expertise, the client was able to generate $2 million in EBITDA and reduce working capital by $6 million.

The Challenge

A $65 million consumer audio electronics manufacturer specializing in high end luxury audio components was facing decreasing sales and declining margins. Although their products are sold through the largest electronics chains in North America and specialty stores worldwide, they continued to see a decline in profit and quality while simultaneously struggling with inefficient utilization of resources. The client turned to TriVista to leverage our expertise in Operational Excellence and best practices within the manufacturing sector.

Our Approach

TriVista’s team of operations experts applied Lean Six Sigma methodologies to evaluate and improve the entire manufacturing process. Utilizing such tools as Pareto Charts, DMAIC Principals (Define, Measure, Analyze, Improve, and Control) extensive employee interviews, Process Maps, Value Stream Maps, Spaghetti Diagrams, and Gemba Walks, the team was able to construct an accurate representation of the client’s current state operation. Once this baseline understanding was established, the team identified several areas of improvement that would result in significant cost savings.
Upon completion of the initial evaluation, the client retained TriVista to lead the company through key project initiatives, including lean manufacturing implementation and sales, inventory, and operations planning improvements.
Areas addressed included:

• Sales & Operations Planning
• Inventory Analysis & Management
• Procurement
• Operational Performance
• Statistical Modeling & Analysis