Food & Beverage
#01
Wholesale Health Food Distributor: $1.25M saved, output up 7.4%, labor cost down 5.9%
$1.25M annualized savings; 7.4% pounds per labor hour; 5.9% labor cost per pound reduction; 56% above identified savings opportunity
Services Industry
#02
Wholesale plant grower: 3.9-to-1 ROI, propagation up 65%, peak-week crews cut 11.5%
3.9-to-1 return on investment; 65% propagation rate gain; 11.5% peak-week workforce reduction; 28% potting rate gain; 23% peak-week carts per hour; 18% hours per cart shipped
Food & Beverage
#03
Midwestern turkey producer: $2M+ saved, load up 63%, overtime down 18%
$2M+ annual savings; 63% maintenance load improvement; $1.225M mro savings; $845K labor savings; 18% overtime improvement
Automotive
#04
Tier 1 Automotive Manufacturer: $1.2M saved, productivity up 30%, OTIF up 80%
$1.2M annualized savings; 30% productivity improvement; 80% on-time-in-full improvement; 87% overtime reduction
Automotive
#05
Tier 1 metal supplier: changeover cut 50%, UPLH up 26%, 300+ ft travel gone
50% changeover time reduction; 26% units per labor hour; 300+ ft forklift travel eliminated
Pharmaceuticals
#06
Global specialty pharma: 93% of products scheduled, rhythm wheel built in 5 weeks
93% products scheduled; 5 weeks time to deliver
Pharmaceuticals
#07
Specialty pharma manufacturer: release time cut 46%, days in lab down 67%
46% product release time reduction; 67% days in lab; 85% time to begin sample testing; 36% lab test cycle time
Food & Beverage
#08
Specialty baked goods manufacturer: productivity up 19%, losses down 28%, overtime down 21%
19% productivity increase; 28% material losses reduction; 21% overtime reduction
Services Industry
#09
Special-Risk Accident Insurer: backlog down 70%, cost per claim down 30%
70% claims backlog reduction; 30% cost per claim; 40% claim processing time; 30% productivity increase; 70% overtime reduction
Food & Beverage
#10
Snack manufacturer: productivity +16%, on-time +16%, changeover downtime -25%
16% productivity increase; 16% on-time delivery improvement; 99% schedule attainment; 25% changeover downtime reduction
Industrial Manufacturing
#11
Professional Safety Products Manufacturer: boxing up 34%, shipping up 52%, OTD up 36%
34% boxing productivity gain; 52% shipping performance increase; 36% on-time delivery improvement; 20% top-customer otd gain
Food & Beverage
#12
RTD beverage manufacturer: first-pass quality up 43%, 16 inspection points installed
43% first-pass quality improvement; 16 critical inspection points
Food & Beverage
#13
Ready-to-eat meats processor: $70M recouped, labor cut 27-33%, downtime down 62%
$70M total savings; 27-33% direct labor cost reduction; 62% equipment downtime reduction; 15-19% operating efficiency improvement; 4% overhead reduction; 2% yield increase
Consumer Products
#14
Raw pet food manufacturer: $7M inventory freed, working capital cut 20%
$7M inventory savings; 20% working capital reduction
Services Industry
#15
Major QSR franchisee: 400+ leaders mobilized, 10 restaurants integrated, culture systematized
400+ leaders mobilized; 10 restaurants integrated; 1 Year performance foundation
Consumer Products
#16
Puerto Rico distributor: receiving up 64%, picking up 35%, overtime down 16%
64% receiving productivity; 35% picking productivity; 16% overtime reduction; 7% outbound productivity
Food & Beverage
#17
Protein manufacturer: $1.25M saved, give-away cut 17.8%, yield held
$1.25M annualized savings; 17.8% give-away reduction; ≤2.5% peak-day yield loss; 66.7% bloodloss reduction; 50% sanitation loss reduction; 16.9% grind inedibles reduction
Food & Beverage
#18
Major poultry producer: new plant to full ramp in 90 days, on plan
90 Days startup to full ramp; On Plan budget and schedule
Food & Beverage
#19
Large-Scale Poultry Processor: spend cut 39.5%, CMMS up 33.4%, PM up 22.6%
39.5% maintenance spend reduction; 33.4% cmms hours utilization; 22.6% pm completion; 17.0% corrective work order completion; 9.1% safety training compliance; 7% startup success
Food & Beverage
#20
Poultry cold storage DC: $4.5M+ saved, productivity up 57%+, on-time shipping up 46%
$4.5M+ annualized savings; 57%+ productivity improvement; 46% on-time shipping; 76%+ overtime cost reduction; 41% labor cost per case; 50% turnover reduction
Food & Beverage
#21
Global potato processor: sanitation cut to 18 hrs, mechanic utilization 35% to 80%
18 hrs sanitation turnaround; 35% to 80% mechanic utilization
Food & Beverage
#22
Midwest pork processor: $10.8M saved, $6.5M yield recovered in 40 weeks
$10.8M annualized savings; $6.5M yield recovery; $2.6M maintenance savings; 19% maintenance overtime reduction
Food & Beverage
#23
Plant-based meat manufacturer: capacity up 26% from 46%, OEE +14%, yield +2%
26% capacity utilization; 14% oee improvement; 2% yield improvement; 18% maintenance overtime reduction; 10% mechanic utilization; 5% mechanic load improvement
Food & Beverage
#24
Pie shell manufacturer: 208% annualized ROI, labor efficiency up 50%, filling yield to 89%
208% annualized roi; 50% labor efficiency gain; 89% filling yield; 68% mix performance; 65% pack performance
Consumer Products
#25
Pet food manufacturer: $13.8M saved, capacity up to 68%, quality up 19%
$13.8M annualized savings; 52% processing capacity; 68% packaging capacity; 19% first-pass quality; 48% packaging waste reduction; 23 Weeks time to result
Industrial Manufacturing
#26
Private Equity-Backed Industrial Manufacturer: 17% productivity, 2M lbs/year, 0 added staff
17% productivity increase; 2M lbs annual production increase; null added headcount
Industrial Manufacturing
#27
Packaging manufacturer: $1M+ saved, units per labor hour up 27%, labor cost down 18%
$1M+ annualized savings; 27% units per labor hour; 18% direct labor cost reduction; 30% quality ncmr reduction; 11% changeover time reduction; 22% machine setup reduction
Food & Beverage
#28
National food manufacturer: 11% labor productivity, 33% throughput, 10% cost cut
11% labor productivity gain; 33% throughput increase; 10% direct labor cost reduction; 97% capacity utilization; $750K identified annual savings; 4 to 0.5 monthly safety recordables
Services Industry
#29
National Medical Supply Distributor: $2.4M saved, overtime cut 47%, labor down 9%
$2.4M annualized savings; 47% overtime reduction; 9% labor cost reduction; 3% productivity per labor hour
Consumer Products
#30
Medical and personal care manufacturer: labor cost cut 30%, startup up 50%
30% labor cost reduction; 50% startup performance improvement; 29 positions optimized
Industrial Manufacturing
#31
Global medical device manufacturer: $4.5M saved, 25% line gain, 15% more output
$4.5M annual savings; 25% line productivity gain; 15% more production, same resources; 40% cell output gain; 21% inspection data-entry time; 10% labor to build one product
Food & Beverage
#32
Global meat processing leader: on-time startups 52% to 91%, overtime cut 17%
52% to 91% on-time startups; 8% pounds per labor hour; 17% overtime reduction
Food & Beverage
#33
Meat packing leader: $5.8M saved, ham yield 99% to 104%, 75-week slide reversed
$5.8M annualized savings; 99% to 104% ham yield; 22% product giveaway reduction; 83% to 92% on-time performance; 18% to 9% operational downtime; 45% scheduling accuracy gain
Food & Beverage
#34
Mass Retail Poultry Processor: $6M saved, yield up 6%, overtime cut 45%
$6M total savings; 6% second-processing yield increase; 45% overtime cost reduction; 48% whole-bird condemned reduction; $1.6M dark meat yield recovery; 2% regular labor cost reduction
Industrial Manufacturing
#35
Large manufacturing operation: $6.3M saved, labor productivity up 26.9%
$6.3M annualized savings; 26.9% labor productivity improvement; 40% gemba health score improvement; $122K weekly efficiency gains
Industrial Manufacturing
#36
Library and archival supply company: $2.1M saved, productivity +20%, service +35%
$2.1M annual labor savings; 20% overall productivity improvement; 35% customer service performance; 20% manufacturing performance
Industrial Manufacturing
#37
Library and archival supply company: MOS rebuilt, workstation output up 15-20%
15-20% high-volume workstation performance
Food & Beverage
#38
Food and ingredients manufacturer: $42.2M saved, 620% ROI, no work cut
$42.2M annualized savings; 620% annualized roi; 33.5% outside labor cost reduction; 22.7% outside r&m cost reduction
Automotive
#39
International automaker: stoppage 4.6% to 1.4%, OEE up to 103%, productivity +17%
4.6% to 1.4% line stoppage; up to 103% oee gain; 17% productivity increase; 65% wait-time reduction; 39% first-pass approval gain; 50s to 30s foamer cycle time
Industrial Manufacturing
#40
Industrial Safety Products Manufacturer: boxing up 23%, shipping up 17%
23% boxing productivity gain; 19% cutting line productivity gain; 17% daily shipping revenue increase; 15% smart line productivity gain; 1,000/shift boxing output target met
Building Products
#41
Industrial Lumber and Packaging Supplier: $500K saved, labor down 12 pts, delivery at 100%
$500K annualized savings; 100% on-time delivery; 12 pts labor cost reduction; 12 pts gross margin gain; 20% network contribution; 5,000 sq ft floor space freed
Food & Beverage
#42
Major independent poultry producer: $30M turnaround, $4-5M saved at one plant
$30M business turnaround; $4-5M single-plant savings; $3M parts and materials savings
Industrial Manufacturing
#43
Home furnishings: 49% productivity gain, $2M+ saved, wages up
$2M+ annualized savings; 49% productivity gain; 12% labor cost reduction with wage increases; 40% volume increase, sustained; 133K sq ft floor space recovered; 18% cost per unit reduction
Food & Beverage
#44
Hamburger Patty Processor: $1M saved, yield up 1%, productivity up 16%
$1M annualized savings; 1% yield improvement; 16% productivity increase
Services Industry
#45
Group insurance contracts: on-time up 60%, aged backlog down 62%, 3 years of growth absorbed
60% on-time completion; 62% aged-case backlog reduction; 3 Years growth capacity unlocked; 50% 30-day backlog reduction; 8% efficiency gain
Food & Beverage
#46
Global Nutrition Company: OEE 71% to 95%, $2.36M conversion cost cut
$2.36M conversion cost reduction; 71% to 95% oee; 19.8% production increase; $1.48M contractor cost reduction; $927K quality claims reduction; 54% to 7% turnover reduction
Metals & Mining
#47
Global aluminum producer: $2.0M saved, throughput up 28%, sow quality up 60%
$2.0M annualized savings; 28% throughput increase; 60% sow quality increase; 59% bar attainment; 49% table efficiency; 15% coil yield
Food & Beverage
#48
Frozen Food Manufacturer: $2.53M saved, MUV cut 73%, productivity up 41.8%
$2.53M savings realized; 41.8% productivity improvement; 73% material usage variance reduction; 91% schedule attainment
Food & Beverage
#49
Major food processor: $6.1M annualized savings, verified by finance
$6.1M annualized savings
Food & Beverage
#50
Large-Scale Food Processor: uptime and reliability up 34%+ in three months
34%+ uptime and reliability improvement
Food & Beverage
#51
North American Food Manufacturer: zero safety incidents, zero quality escapes
Zero safety incidents; Zero quality escapes
Food & Beverage
#52
Food manufacturer: $3.46M annualized, 6% performance gain, 12% less waste
$3.46M annualized savings; 6% performance improvement; 12% waste reduction; $344K 12-week sprint savings
Food & Beverage
#53
Family meat processor: throughput up 47%, labor cost down 3.4%/lb, yield up 0.41%
47% throughput increase; 3.4% direct labor cost per pound; 0.41% yield improvement; 0.29% inedible product reduction; >85% maintenance labor utilization
Food & Beverage
#54
Established food manufacturer: $4M+ saved, productivity up 19%, overtime cut 32%
$4M+ annualized savings; 19% productivity improvement; 32% overtime reduction
Energy & Utilities
#55
Global renewable energy manufacturer: $1.2M added profit, overtime cut 50%
$1.2M added annual profit; 50% overtime reduction
Food & Beverage
#56
Global Dairy Producer: 41% productivity gain, rework cut 46%, 48,000 lbs/hr held
41% packaging productivity; 46% rework reduction; 48,000 lbs/hr packaging capacity; 8 Weeks time to roi roadmap
Food & Beverage
#57
Northeastern dairy and coffee producer: $6.7M saved, packaging up 36.9%, line up 33.4%
$6.7M recurring annual savings; 36.9% packaging productivity; 33.4% evaporator line productivity; 30% cip cycle time reduction; 30% tank changeover improvement
Consumer Products
#58
Global consumer-goods manufacturer: throughput up 36%, OEE up 10%, uptime up 5%
36% throughput improvement; 10% oee improvement; 5% plant uptime increase; 10% line startup improvement
Food & Beverage
#59
Coated foods manufacturer: on-time 78% to 92%, 92% uptime, output up 9%
78% to 92% on-time performance; 9% daily output; 92% uptime; 50% scheduling accuracy gain
Food & Beverage
#60
Major beverage manufacturer: 7% output gain, utilization recovered, accuracy 23% to 88%
7% yoy output gain; 46% to 76% mechanic utilization; 23% to 88% material location accuracy; 40% to 88% maintenance schedule compliance; 80% truck wait-time reduction; 23% to 14% mechanic overtime
Food & Beverage
#61
Major Beef Processor: $2.3M saved, R&M cut 13%, planned work at 108%
$2.3M maintenance savings; 13% r&m spend improvement; 18% regular hours reduction; 12% overtime reduction; 108% planned work completion; 80%+ startup score
Food & Beverage
#62
Pre-cooked BBQ manufacturer: $2.2M projected savings, yield up 1.5%, OEE up 10%
$2.2M projected annual savings; 1.5% yield gain; 10% oee increase; 27% rework efficiency gain
Food & Beverage
#63
Consumer baked goods producer: $3.4M OEE savings, Power Hour up 50%, OEE up 14%
$3.4M oee savings; 50% power hour increase; 73% schedule attainment increase; 14% overall oee improvement
Automotive
#64
Automotive Aftermarket Parts Manufacturer: 20% productivity gain, safer flow, room to scale
20% productivity increase
Food & Beverage
#65
Animal Nutrition Supplier: 2.09:1 ROI, labor hours down 4.5%
2.09:1 return on investment; 4.5% labor hours reduction
Food & Beverage
#66
Animal Nutrition Producer: scrap cut 65%, COPQ down 45%, temp labor down 15%
65% scrap reduction; 45% cost of poor quality reduction; 15% temporary labor reduction
Food & Beverage
#67
Global private agribusiness: 13 HR policies standardized, 10 core processes mapped
13 hr policies standardized; 10 core processes mapped; 100+ experts aligned
Chemicals & Refining
#68
Global Agribusiness Manufacturer: throughput up 24%, uptime up 11%, startups up 73%
24% throughput increase; 11% uptime improvement; 73% startup score improvement; 102% schedule attainment; 100% overtime reduction
Industrial Manufacturing
#69
Home furnishings: 49% productivity gain, $2M+ saved, wages up
$2M+ annualized savings; 49% productivity gain; 12% labor cost reduction with wage increases; 40% volume increase, sustained; 133K sq ft floor space recovered; 18% cost per unit reduction
Aerospace & Defense
#70
Defense manufacturer: 56% to 89% on-time performance
59% on-time performance; 65% lead time reduction; 69% lost time reduction; 56% indirect time reduction; 22% stock room output gain; 20% scheduling accuracy gain