The Challenge
Improvement that wouldn't stick
The plant needed results it could verify to the bottom line, fast — and it needed them to hold. Prior gains faded because there was no shop-floor management system and no daily discipline to sustain them. The work had to change the culture, not just the metrics.
The Approach
Change the culture on the floor
- ▸Implement a Toyota Production System-based shop-floor management system
- ▸Install daily and visual management so the floor sees and owns its own performance
- ▸Deploy Standardized Work so improvements become the new baseline, not a temporary spike
- ▸Tie every improvement to a verified bottom-line number — no soft savings
The Outcome
Measurable results
- ✔$4.2M in verifiable bottom-line savings within six months
- ✔A shop-floor management system owned by the plant, not dependent on outside presence
- ✔A cultural shift toward continuous improvement that outlasted the engagement