Cutting conversion cost by 31% across three plants in nine months.

Faced with margin compression from buyer pressure, rising electricity tariffs, and labor cost inflation, the client had already absorbed 11% of cost increases over 18 months. Their internal lean program had stalled at the production line, never reaching the planning, procurement, or maintenance functions where the largest savings remained trapped.

1. 01

   Diagnostic phase: 14 days, 38 executive interviews, three plant walkthroughs, baseline analysis of seven cost categories.

2. 02

   Embedded teams of two consultants per plant working alongside plant managers and IE teams.

3. 03

   Production planning system rebuilt from order entry through finished goods, with weekly cadence at the operating committee level.

4. 04

   Internal change-agent academy: 84 candidates trained over six cohorts, with capstone projects measured against documented savings.

5. 05

   Independent audit at month twelve, verifying that 78% of documented savings were sustained without our presence.

• ✓31% conversion cost reduction across all three plants
• ✓$48M annualized savings, audited and verified by client finance team
• ✓22% SMV (Standard Minute Value) improvement on flagship product line
• ✓84 internal change agents trained — 76 still active 12 months later
• ✓Renewed for follow-on engagement in two adjacent business units