Raw‑to‑FG Kanban Drives 75% Faster Lead Times and Returns a Business Unit to Break‑Even
Industry: Trash & Recycling Equipment Manufacturing
Company Size: < 1,000 employees
Ownership: Private Equity
The Challenge:
High option variability, long‑lead purchased components, and shared materials across models created chronic shortages and delays—hurting responsiveness and profitability.
Our Approach:
Value Stream Analysis: Mapped constraints, defects, and capacity limits across purchasing, planning, and production.
End‑to‑End Pull: Established Kanban signals and visual controls from raw materials to finished goods.
Visual Management: Built daily‑use visuals to surface problems and trigger real‑time problem solving.
Front‑Line Ownership: Operators designed part storage and material handling; improvements replicated at a second facility.
The Results:
34% efficiency improvement
75% faster order‑to‑ship capability (4 weeks → 1 week)
90% reduction in obsolete and slow‑moving inventory
Returned to financial break‑even within one year
Why It Matters
End‑to‑end pull stabilizes material availability, eliminates delays, and accelerates cash conversion—enabling growth and margin recovery.
Services & Tools: Value Stream Analysis, Pull/Kanban, Visual Management, A3 Problem Solving, Root Cause Analysis, Replication Playbook
