Case studies

Before and after, from the factory floor.

Three projects, with the baseline, the tools used and the results. Pick one, tell us where to send follow-up, and the PDF downloads right away.

Turnaround
19% to 31%
Gross margin in 12 months

90-Day Manufacturing Turnaround

An Ontario manufacturer moved from cultural breakdown to a stable operation. Staff turnover fell from 65% to 22% and complaints from 24 to 5 a month.

Culture resetDaily huddlesStandard work
14 pages · PDF
DMAIC · Six Sigma
69% to 98%
On time, in full, correct

On-Time Delivery DMAIC

Two glass sites, one broken order flow. Lead time went from 3 days to 1, with about $254,000 in estimated net savings audited by Finance.

VSMFishbone5 WhysPoka-yokep chart
27 pages · PDF · Led by our founder before OpsAlign
Kaizen event
88% to 99%
Liner table efficiency

Kit Room Kaizen

Too much walking for tools and material. Time studies, a spaghetti diagram and point-of-use storage removed the bottleneck.

Time studySpaghetti diagram6SPoint of use
11 pages · PDF

Client and site details are anonymised. Results are reported by OpsAlign, and every factory is different.

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