CATEGORIES: Building Products, Case Study, Cost Reductions, Improved Efficiencies, Manufacturing
HVAC Materials Manufacturer Increase Revenue
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, this rapid growth also magnified the shortcomings of LL’s management infrastructure, resulting in communication breakdowns, widespread inefficiencies, and poor employee morale.
About the Client
LL Building Products is a manufacturer of ventilation systems and HVAC materials—products sold in tandem with roofing supplies — making this new subsidiary a natural complement to GAF’s business.
Financial Results Snapshot
DB&A Delivered
- 20% increase in efficiency
- 50% reduction in temporary labor requirements
- 67% average decrease in scrap
- 45% reduction in inventory, resulting in $3,000 monthly savings on outside warehouse costs
- 29% reduction in overtime
Related Work
Agribusiness Transforms Culture to Exceed Fiscal Goals
Agribusiness Transforms Culture to Exceed Fiscal Goals CATEGORIES: Case Study, Improved Efficiencies, Manufacturing, Productivity / Throughput, Workforce Engagement The Challenge An agribusiness manufacturing facility was facing persistent leadership and communication challenges. The company’s decision-making often resided with a small group of individuals, reinforcing departmental silos and limiting collaboration across teams. This structure left many employees...
Pharmaceutical Packaging Company Unlocks Performance
Pharmaceutical Packaging Company Unlocks Performance CATEGORIES: Case Study, Improved Efficiencies, Manufacturing, Medical, On-Time Deliveries, Productivity / Throughput, Workforce Engagement The Challenge As market demand accelerated and growth opportunities increased, the organization faced internal challenges that threatened to stall its momentum. Senior leaders found themselves entrenched in daily operations, leaving little time for strategic focus to...
Mining Operations Overcomes Efficiency Challenges
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...
Praxis Empowers Front-Line Leaders and Regains Competitive Edge
Praxis Empowers Front-Line Leaders and Regains Competitive Edge Praxis Packaging has grown into a multifaceted national packaging center serving the pharmaceutical, over-the-counter medications, and nutritional industries over the span of 35 years. The company was recently acquired by a private equity firm, with the focus of having management grow the top line, while also improving...