MetaExpert Transforms a Family-Owned Business into a Corporate World-Class Organization

Situation

  • The company was a family-owned business manufacturer of custom wood front doors, acquired by a large manufacturing corporation of products for the construction / distribution industry,
  • The operation had a unique design of products but wasn’t meeting the sales and financial goals.
  • The manufacturing process was rudimentary with lack of controls, process standards, procedures, metrics, and poor materials inventory control & planning.

Actions

  • Facilitated an event to identify potential business growth, evaluating the sales performance activity, gathering information to enable product mix and sales strategy decision making using the VOC.
  • Evaluated the market needs, pinpointed opportunities, defined key initiatives and created action sales plans aimed at selective customers.
  • Facilitated the materials team to develop and implement an MRP and inventory control system.
  • Conducted Kaizen Events with the team and re-layout the production process.
  • Spearheaded a deep analysis at the Gemba, to review all activities with the owners to uncover and identify Mudas and improvement opportunities.
  • The team used lean tools such as Waste, 5S, 5Why, Poka Yoke, FMEA, One Piece Flow, Ergonomics, TPM and Kan Ban.
  • Led a cross functional quality improvement team, training them on QFD, PDCA, Impact Indicators, reaction to out of control condition, root cause analysis, 5Why, Fish bone analysis, (Ishikawa), operations standards and cross training.
  • Performed a financial quantification of improvements benefits and formulated a plan to enabled measurement of benefits.
  • Confirmed the current state and defined the future state; generated a plan of improvements fitted to the organization’s direction and long-range goals.

Results

  • Transformed an organization from a family-owned business to a corporate world-class organization, delivering positive financial results and positioning the plant team and products for success.
  • Emergence of new organization with a lasting continuous improvement culture where involvement at every level from senior leadership to individuals on the production floor leverage their capabilities to create a competitive advantage.

Return on Investment

Cost reduction savings over $200K per years, sales grew 300% and exceed profitability goals.

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