Mining Operations Overcomes Efficiency Challenges CATEGORIES: Case Study, Customer Satisfaction, Improved Efficiencies, Machine Utilization, Maintenance, Mining, Productivity / Throughput The Challenge Despite a strong culture and low turnover rates, the company had missed its budget targets for two consecutive years. In 2022, the company missed its delivery goal by 24,000 ore tons In 2023, it...

Packaging Company Regains Competitive Edge CATEGORIES: Case Study, Cost Reductions, Customer Satisfaction, Food, Improved Efficiencies, Medical, Private Equity, Productivity / Throughput The Challenge Praxis Packaging was recently acquired by a private equity firm, with the focus of having management grow the top line, while also improving productivity, reducing costs, and enhancing competitiveness, to win new...

Communications Company Improves Planning and Processes, Increases Profit CATEGORIES: Case Study, Cost Reductions, Improved Efficiencies, Productivity / Throughput, Telecommunications The Challenge A turn-key solution-based Telecommunications, Broadband & Wireless organization was experiencing increased costs resulting in much lower profitability than previous years. They reached out to DB&A for help identifying operational and financial opportunities to increase...

Railway Maintenance Shop Gets On Track with Large Manufacturing Contract CATEGORIES: Case Study, Customer Satisfaction, Improved Efficiencies, Manufacturing, On-Time Deliveries, Productivity / Throughput, Transportation The Challenge A family-owned railway maintenance and repair company with nearly 70 years in the industry was awarded a contract that would transform their business. The company received an order for...

Sausage Manufacturer Meets Increased Demand CATEGORIES: Case Study, Food, Improved Efficiencies, Machine Utilization, Manufacturing, Productivity / Throughput The Challenge The year 2020 created unprecedented challenges for a sausage manufacturer, who experienced a 100% decline in sales of stadium sausages while seeing an 100% increase in demand in packaged ready-to-eat sausage products sold in grocery stores....

Culture Change Energizes Midwest Coal Plant CATEGORIES: Case Study, Cost Reductions, Energy, Improved Efficiencies, Productivity / Throughput The Challenge An energy provider in the Midwest was looking to keep a major fossil fuel powered asset in service amid an ever-increasing reliance on renewable energy. With the reliance on coal decreasing and the costs of generating...

Tools Manufacturing Client Changes Off-Shore Strategy CATEGORIES: Case Study, Distribution, Improved Efficiencies, On-Time Deliveries, Productivity / Throughput, Sales The Challenge The company was facing increasing labor and material costs and had developed a strategic model in which manufacturing capabilities were to be moved overseas. Covid-19 brought new challenges and opportunities beginning in March 2019. The...

Client Improves Culture, Retains Family Atmosphere CATEGORIES: Case Study, Distribution, Improved Efficiencies, Manufacturing, Medical, On-Time Deliveries, Productivity / Throughput The Challenge Despite working excessive amounts of overtime, employees were still not able to meet their on-time delivery schedule or satisfy customer requirements. Orders remained constant, but inventory was building as there were disconnects in their...

Solving Problems on the Front-Lines CATEGORIES: Case Study, Cost Reductions, Improved Efficiencies, Manufacturing, Productivity / Throughput The Challenge At the client's Tennessee location, leadership identified issues concerning culture and behavioral patterns that resulted in inefficient performances causing an impact on the bottom line, profitability. About the Client A global leader in drivetrain and e-Propulsion systems...

Defense Manufacturing Facility Increases Productivity CATEGORIES: Aerospace, Case Study, Defense, Distribution, Improved Efficiencies, Manufacturing, Productivity / Throughput The Challenge DB&A was also tasked to initiate and implement change in the culture in each area of operations. Concerns arose regarding current practices, facility maintenance, key equipment maintenance, and production uptime. DB&A understood the concerns and successfully...

Improved Performance Drives Savings CATEGORIES: Aerospace, Case Study, Cost Reductions, Defense, Improved Efficiencies, Productivity / Throughput The Challenge The client was looking to create financial capacity in order to upgrade their technical talent and scale its growth through systems and processes. About the Client The client, a global provider of products, services, and solutions for...

Standard Processes Increase Output CATEGORIES: Automotive, Case Study, Improved Efficiencies, Manufacturing, On-Time Deliveries, Productivity / Throughput, Transportation The Challenge The company reached out when their on-time delivery rate had dropped to 60% at one of their plants. They needed to ramp up their ability to consistently meet the growing demand for their parts and knew...

Steel Mill Achieves Consistent Quality CATEGORIES: Case Study, Improved Efficiencies, Machine Utilization, Maintenance, Manufacturing, On-Time Deliveries, Productivity / Throughput, Quality, Scrap The Challenge The client was working to implement an advanced tool set and struggling to meet the precise process controls required. These quality control issues created delays in production, increases in re-work, and excessive...

Aircraft Distributor Improves Fulfillment CATEGORIES: Aerospace, Case Study, Cost Reductions, Distribution, Improved Efficiencies, Private Equity, Productivity / Throughput The Challenge The primary objectives were to improve warehouse fulfillment rates and reduce the cost per transaction. About the Client One of the world's leading independent distributor and provider of comprehensive supply chain management services to the...

Stellar Increases Production with Existing Resources CATEGORIES: Automotive, Case Study, Customer Satisfaction, Nuclear, Quality, Safety The Challenge The company was experiencing a large backlog of orders and losing customers to their competition. About the Client Stellar Industries, headquartered in Garner, Iowa began in 1990 with the first USA made domestic hydraulic hoist. The company is...

JOA Project Shifts Amid Pandemic CATEGORIES: Case Study, Cost Reductions, Manufacturing, Medical, On-Time Deliveries, Productivity / Throughput The Challenge DB&A was engaged to help JOA understand why they were experiencing increased costs and extended delivery times. About the Client Since 1932, Curt G. JOA, Inc. has been known for innovation in the disposable hygiene industry....

Services for Private Equity Firms CATEGORIES: Case Study, Improved Efficiencies, Private Equity, Productivity / Throughput, Sales About the Client Private Equity firms do an excellent job analyzing potential investments and current portfolio companies. However, most do not possess the “Shop Floor” operations expertise required to evaluate problems and determine the savings and efficiency improvements available...

Front-Line Leaders Make Positive Changes CATEGORIES: Case Study, Customer Satisfaction, Energy, Nuclear, Quality, Safety The Challenge DB&A was brought in to be a part of the company's efforts toward the standardization of their metrics and tools for managing the business. DB&A’s services and expertise was utilized in assisting with the need to drive accountability around...

Planning Improves Productivity CATEGORIES: Case Study, Cost Reductions, Customer Satisfaction, Machine Utilization, Manufacturing, On-Time Deliveries, Productivity / Throughput The Challenge The company had a growing backlog and customers became frustrated with the longer lead times. They reached out to DB&A to help decrease production times, increase profitability, reduce overtime, while achieving established sales targets. About...

Software Project Completed Early CATEGORIES: Aerospace, Case Study, On-Time Deliveries, Productivity / Throughput The Challenge The client was behind schedule for a software development project and over budget. They wanted a “12-week boot camp” in order to maximize the opportunity to meet their project deadline. The client had 152 Software Engineers across Florida, New York,...

Plastics Manufacturing Increases Productivity Without Incurring Additional Costs CATEGORIES: Case Study, Cost Reductions, Machine Utilization, Manufacturing, Productivity / Throughput DB&A’s management consulting approach helped a client in plastics manufacturing increase productivity. We delivered a customized management operating system to create standard work and predictability of results. Overall culture improved as employees, managers, and supervisors established...

DB&A Honors Financial Guarantee CATEGORIES: Case Study, Customer Satisfaction, Manufacturing, On-Time Deliveries, Productivity / Throughput, Scrap The Challenge Supervisors performed inconsistently and their reactive management style was driving significant amounts of lost time, excessive scrap, and slowdown in production; resulting in a poor customer experience. About the Client A global leader in the formulation of...

An Aircraft Maintenance and Repair Company Reduces Costs, Improves Performance CATEGORIES: Aerospace, Case Study, Cost Reductions, On-Time Deliveries The Challenge The client's Grand Junction, Colorado facility was experiencing less than satisfactory productivity, excessive rework, and excessive labor costs to meet customer deadlines. About the Client West Star Aviation is an aircraft repair, maintenance, and refurbishing...

Call Center Experiences Higher Call Volumes CATEGORIES: Call Center, Case Study, Cost Reductions, Customer Satisfaction, Productivity / Throughput The Challenge One of the client's call centers began experiencing a slowdown in call volumes. About the Client As a student loan servicer with 25 years of experience, the Client works to provide support to students and...

Biological Testing Company Gets Its Business Practices Down to a Science CATEGORIES: Case Study, Machine Utilization, Medical, Productivity / Throughput The Challenge The company, while recognized as a leader in science, realized that many of the company’s PhD-educated managers lacked the business experience necessary to improve internal processes which was hurting the bottom line. BioReliance’s...

Seed Processing Facility Strives to Meet Global Customer Demand CATEGORIES: Case Study, Food, Manufacturing, Productivity / Throughput The Challenge The client was making business decisions primarily based on revenues. They wanted to meet growing customer demand as well as improve delivery times. About the Client The client is a seed-processing facility producing high-quality vegetable seeds....

MRO Provider Diversifies From Government to Commercial Market CATEGORIES: Aerospace, Case Study, Cost Reductions, Productivity / Throughput The Challenge The client was under tremendous pressure to change the culture from a government contractor to a strong service provider to commercial customers. Years of federal funding had covered up inefficiencies. About the Client The client is...

Improving Efficiency and Productivity for a Private-Equity Holding Organization CATEGORIES: Case Study, Manufacturing, Private Equity, Productivity / Throughput The Challenge Operations at the fiberglass fishing boat company needed to be improved and brought in-line with the companies goals. About the Client The client is a Private Equity holding organization. They had acquired several recreational and...

Helping a Private Equity Client Add Value by Driving Improvements CATEGORIES: Aerospace, Case Study, Cost Reductions, On-Time Deliveries The Challenge Workers were spending time waiting for machines to break-down for repair—then reacting—versus performing preventative maintenance. Also, front-line supervisors in the maintenance area had few established metrics to drive decisions. The management culture was well-intentioned and...

HVAC Materials Manufacturer Increase Revenue CATEGORIES: Building Products, Case Study, Cost Reductions, Improved Efficiencies, Manufacturing The Challenge LL Building Products was not operating at its full potential at the time it was acquired. As a primary supplier to Home Depot, LL had grown quickly to keep pace with the home improvement giant's expanding operations. Unfortunately,...

Defense Contractor Improves Productivity and On-Time Delivery CATEGORIES: Case Study, Cost Reductions, Defense, Productivity / Throughput, Scrap The Challenge The company’s Steel Products Division began to lose significant ground in the areas of on-time delivery, productivity, and excess scrap. About the Client United Defense, a major defense contractor with facilities throughout the United States, started...

Electronics Company Redefines its Performance Culture After Spinoff CATEGORIES: Case Study, Cost Reductions, Electronics, Productivity / Throughput The Challenge The client had a desire to create their own identity by establishing a vibrant, performance based culture. However, with customer satisfaction at 99%, the challenge of getting the organization to see the need for change would...

Truck Parts Manufacturer Improves Maintenance Practices CATEGORIES: Automotive, Case Study, Cost Reductions, Maintenance, Productivity / Throughput, Transportation The Challenge The client needed help with installing a uniform management system across the entire facility and improving the throughput and productivity of the manufacturing plant. About the Client The Client, with an emphasis on technological leadership and...

Satellite Manufacturer Reduces Costs and Increases Production CATEGORIES: Aerospace, Case Study, Cost Reductions, Productivity / Throughput The Challenge Space Systems/Loral needed a more proactive management culture and new operational processes and training tools to help them reduce costs, increase production without compromising quality, and help the company increase its market share in the highly competitive...

Government Agency Improves On-Time Delivery CATEGORIES: Case Study, Defense, Government, On-Time Deliveries The Challenge Despite the generous lead times, Naval Sea Systems Command (NAVSEA) — the government agency responsible for these projects—was missing deadlines and losing financial ground by the millions. About the Client Naval Sea Systems Command (NAVSEA) is the government agency to deliver...

Family-Owned Company Improves Management Skillsets CATEGORIES: Case Study, Food, Machine Utilization, Productivity / Throughput, Quality The Challenge Hatfield Quality Meats was experiencing some of the best years in its history. Even so, they were looking for ways to improve and keep their competitive edge in an industry dominated by large conglomerates. About the Client A...

Medical Device Manufacturer Improves Productivity CATEGORIES: Case Study, Machine Utilization, Manufacturing, Productivity / Throughput The Challenge The client was seeking to make improvements in scheduling inconsistencies, imbalanced allocation of staff members, machine maintenance scheduling, and to fix backlogs and bottlenecks in the production line. About the Client The Client is a leading developer, manufacturer, and...

Steel-Production Facility Increases Efficiency and Reduces Costs CATEGORIES: Case Study, Cost Reductions, Improved Efficiencies, Machine Utilization, Manufacturing The Challenge The client realized they needed help to increase efficiencies, strengthen the company's balance sheet, and enhance its competitive position. About the Client Atchison Steel Casting and Machining was going through challenging times following the bankruptcy of...

Nuclear Plant Significantly Improves Resource Utilization CATEGORIES: Case Study, Cost Reductions, Energy, Improved Efficiencies, Nuclear, On-Time Deliveries, Productivity / Throughput The Challenge Senior leaders were concerned about the gaps in managerial and front-line supervisory skill sets. About the Client This client is one of the nation’s largest nuclear plants. They are committed to nuclear safety...

Call Center “Owns” a New Culture CATEGORIES: Call Center, Case Study, Customer Satisfaction, Quality, Sales, Telecommunications The Challenge The client was noticing a disturbing slowdown in customer consultations and problem-solving responses at the Small Business Call Center serving Kentucky and Tennessee. About the Client The small-business segment of BellSouth (acquired by AT&T) is an important...

Trucking Company Improves Customer Service CATEGORIES: Case Study, Cost Reductions, Customer Satisfaction, Machine Utilization, Productivity / Throughput, Quality, Safety, Transportation The Challenge Our client was seeking to improve load velocity, reduce fuel costs, and increase productivity. About the Client Client provides irregular route, dry van truckload carrier transportation for some of the nation’s largest retailers...

Distribution Center Optimizes Seasonal Workforce CATEGORIES: Case Study, Cost Reductions, Distribution, Retail The Challenge The client recognized they were experiencing an overall business stagnation and that one of the contributing factors was continually increasing costs. Due to the seasonal nature of the business, costs related to the temporary labor force, overtime hours, and inventory needed...

Financial Services Company Improves Customer Care CATEGORIES: Case Study, Cost Reductions, Customer Satisfaction, Financial Services, Productivity / Throughput The Challenge The client was seeking a stronger competitive edge by improving quality, service, and productivity in all call centers, claims processing centers, and shared services offices throughout Canada. About the Client The client is a leading...