On-Time Transportation Rate
Problem: Trip on-time rate at 69% — well below target. Root causes: dispatch delays, driver availability gaps, and no real-time visibility into performance.
Network Consolidation — Headcount Reduction
Problem: Two-facility workflow for priority mail processing generating significant transportation waste, excess handling, and overprocessing across 18 FTEs.
Multi-Site Scrap Reduction
Problem: Scrap variation across 5 manufacturing facilities with no standardized process parameters. Each site operating independently — no shared baseline or corrective action protocol.
Inventory Shrink Reduction
Problem: Inventory shrink measured at 6.8% across stores — driven by theft, damage, and process losses. Root cause, identified through 5 Whys analysis, was not a process failure: it was lack of standardized training.
Tablet Weight Variation — $240K Annual Savings
Problem: Tablet weight variation in pharmaceutical manufacturing causing product failures and significant rework costs. Cpk analysis confirmed the process was operating outside specification. Paddle feeder speed variation identified as the key input variable.
Peak Season Throughput Recovery
Problem: Throughput dropped 40% during scheduled breaks in a high-volume fulfilment operation during peak season. Labour coverage gaps identified through heat map analysis of break timing vs. volume demand.