Client Impacts

Implemented New SIOP Process to Reduce Equipment Downtime by 13% at PE-Owned Printing Manufacturer

Capabilities
Private Equity & Financial Sponsors Industrials & Infrastructure

Challenge

A private equity-owned printer of high-quality graphics and packaging was experiencing declining volumes and eroding operating profits.

The company needed help improving its operational performance and implementing a new Sales, Inventory, and Operations Planning (SIOP) process.

Approach

  • Developed and implemented targeted equipment repair program to critically improve machine performance with minimal capital expenditure
  • Created comprehensive trainings, standard work procedures, and metrics to track and improve employee efficiency on production floor
  • Implemented new cross-functional meetings to ensure optimal schedules are developed and any barriers to operations, quality, or safety are quickly removed
  • Identified and incorporated redundant raw materials components to reduce bloated inventory and minimize COGS

Results

I.

Reduced unplanned equipment downtime by 13% vs trailing 12-month baseline

II.

Improved the percentage of jobs delivered on time from ~70% to ~90% over a 6 month period

III.

Saved 20% in expected material purchasing costs and freed additional working capital through tighter inventory management and smarter usage

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