Performance Improvement: Fabricated Metal Product Manufacturer

Client

Fabricated Metal Product Manufacturer

Needs

  • Our client was struggling to make payroll and feared they would be forced to shutdown the company absent another solution.
  • Management needed help determining whether or not the company should continue as a going concern and, if so, implementing an improvement plan.

Solution

  • Spent the first 24 hours analyzing the company’s recent performance and identifying problems and solutions.
  • Led a weekend planning session with management and other employees and concluded the company needed to radically restructure its operations.
  • Developed a plan to implement the restructuring during the following week.
  • Built operating and cash flow models to measure progress and results.
  • Provided management with long-range performance improvement plan to ensure sustainability.

Results

  • Reduced headcount by 35 employees.
  • Went from operating 24-7 (with related overtime premiums) to two 10-hour shifts, five days a week.
  • Improved on time delivery and reduced scrap and rework.