$27 Million in Productivity Benefits
Integrated operational and technology solutions for a US home appliances manufacturer.
The Challenge
A major US home appliances manufacturer was experiencing declining EBITDA despite stable revenue. Production inefficiencies, quality rework, and excessive inventory were eroding margins. Multiple previous improvement initiatives had delivered short-term gains that faded within months.
The company needed a partner who could deliver lasting operational transformation — not another round of recommendations that would sit in a binder on the CEO's shelf.
Our Approach
Our Business Review identified $27 million in quantifiable improvement opportunities across the production environment — in throughput, quality, maintenance, and inventory management.
We deployed a cross-functional implementation team that worked alongside factory management and operators. The program combined lean manufacturing tools with our iMOS platform to create a management operating system that tracked performance in real time and drove daily accountability.
Training was integrated throughout — not as a separate initiative, but as part of every process change. Supervisors learned to manage by data, operators learned new standard work procedures, and managers learned to coach rather than direct.
