Lean Transformation

Problem:

Protecto Wrap, a company that manufactures products for the construction industry, had grown dramatically and needed transformational help.

Solutions:

We deployed multiple initiatives to help the business. The first step was to develop a top-level dashboard with a line of sight. Concurrently, we altered the scheduling processes while addressing flow in the retail division and deployed daily management.

We then commenced with daily hourly huddles and Gemba. Afterward, we stabilized staffing in critical positions and identified methods for addressing equipment outages.
 Last we restructured the leadership team to support all shop floor positions.

Benefits:

Conversion costs dropped by over 18%, throughput increased by 26%, and working capital fell by 12%. The company started a build-to-stock program, which they had never been able to accomplish in 70 years. Most significantly, they are aligned, engaged, and working as a team.