The Challenge
A 20% cost spike across multiple sites
A global residential HVAC supplier saw a 20% spike in conversion costs, driven by low productivity and an inexperienced management layer — putting revenue at risk across multiple sites simultaneously.
The Approach
The strategic pivot
- ▸Convert C-suite financial goals into shop-floor metrics tied to conversion cost
- ▸Execute and adjust in real time rather than waiting on a perfect rollout plan
- ▸Hold lead time as the ultimate metric to surface hidden productivity loss
- ▸Lock in gains with Standardized Work and direct management coaching across all sites
The Outcome
Measurable results
- ✔$8M in conversion cost savings within three months
- ✔Revenue grew from $75M to $90M per month
- ✔Recovered $17M in lost sales through improved supplier performance