Customer Profiles - Manufacturing

  • AG Growth Industries

  • Kuhn North America

  • Mold Masters

  • Vantage Foods

  • Watts Water Tech

AGProfileTall-179x300AG Growth

is a leading manufacturer of portable and stationary grain handling, storage and conditioning equipment including augers, belt conveyors, grain storage bins, grain handling accessories and grain aeration equipment. 

Amazing Results:

After four months:

• 6,400 square feet saved

• $1,100,000 inventory reduced 

First cell:

• + 12% productivity

• 100% on-time delivery

 

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Kuhn North AmericaKuhn North America

is a leading innovator in the design, production and marketing of agricultural machinery sold throughout the world. 

Amazing Results:

• throughput and productivity gains ranging from 10-75% across 8 manufacturing processes

• 50% reduction in time required to build targeted product

• 70% + reduction in scrap rate for targeted product

• 47% increase in production in one cell (in first 3.5 months)

• 14% reduction in hours required per unit

• a reduction of approximately 2½ man hours below the existing average rates prior to the Lean work

 

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Mold Masters

MoldMastersProfileTall-179x300is a privately-held global company and the world's leading supplier of hot runner technology and systems. 

Amazing Results:

• 33% increase in weekly output

• 2 week reduction in lead times

• 65% reduction in machine set-up time

• 60% reduction in material travel time

• 50% reduction in production time

• incoming orders that previously took 7 days to reach the shop floor are now available to build in less than 2 hours


"The adoption of the LEAN Continuous Improvement Methodology has enabled Mold-Masters to officially launch our Accelerated Delivery program with an advertising campaign in North America that covers many of our most popular system configurations. Mold-Masters has never been better prepared to match or beat any delivery commitment offered by our competitors."

Jonathan Fischer, President & CEO Mold-Masters

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VantageProfileTall-179x300Vantage Foods

is a North American food company offering innovative case-ready solutions for progressive retailers in Canada and the United States. 

Amazing Results:

• 65% reduction in machine set-up time

• 60% reduction in material travel time

• 22% increase in productivity in a targeted value stream, reducing tasks from 70 to 54

• tripled productivity in another value stream by reducing tasks from 345 to 95

• 100% on-time delivery

• zero product staged on shipping dock

 

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watts ACVwsprayWatts Water Technologies

designs and manufactures valves and related products that promote the comfort and safety of people and the quality, conservation and control of water used in commercial, residential, industrial and municipal applications. 

Amazing Results:

• reduction in inventory: 31.2%
• reduction in defects per Unit: 87.5%
• reduction in rework Dollars: 85.2%
• throughput increase: 26%
• productivity (units produced per hours worked: 29.4%
• product yield (reduction in failed units): increase of 85.2%

 

"I was very apprehensive when Watts decided to utilize OTI in our Lean transformation strategy because of my perception that consultants have no long term responsibility and accountability. However, Phil changed my views on consulting. He has a vast knowledge of Lean implementations in a variety of industries with an extremely practical approach.

I personally received the education of my life during the events designed and lead by Phil and am still awed by daily developments resulting from those projects. I guess you can call me a true Lean thoughtware believer!"

Jacques Klopper, Director of Operations, Watts Water Technologies

 

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Customer Profiles - Services

  • Canadian Tire Financial Services

  • Tim Horton Children's Foundation

  • TranSystems

Canadian Tire Financial Services

Canadian Tire Financial Services

is primarily engaged in marketing the Canadian Tire Options® MasterCard® portfolio to four million Cardmembers as the financial services arm of Canadian Tire. 

Amazing Results:

• full end-to-end process reduced by 83%

• queue wait times and duplication of work have been eliminated

• 4 x productivity

• cost is 10% lower

• employees are fully engaged in the Lean process and are empowered to make decisions

“With Phil’s help, we reduced our document processing by 83%. Productivity increased by 400% without working any harder.”

Chris Main, VP Customer Service & Operations, Canadian Tire Financial Services, Canada

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Tim Horton Children's Foundation

Tim Horton Children's Foundation

is a non-profit, charitable organization committed to providing a fun-filled camp environment for children from economically disadvantaged homes.

Amazing Results:

• 50% increase in productivity

• 98% improvement in cycle time

• 93% reduction in registration processing time

• created 200 sq ft of space in mail room

 

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TranSystems

TranSystems

is a transportation consulting company providing integrated solutions for all transportation modes - through every market sector - to move people and products wherever they need to go. 

Amazing Results:

TranSystems has implemented a Performance Management and Measurement System which ties its offices across the country into a single strategic direction. TranSystems' strategy has been translated into action and is everyone's job.

TranSystems' Performance Management and Measurement System serves as a:

• daily Management System, using the scorecard to manage the business more robustly

• problem-solving tool

• Performance Management System

• link between compensation/rewards and individual/team performance

 

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Customer Profiles - Supply Chain

  • Canadian Tire Distribution

Canadian Tire

Canadian Tire Distribution

is Canada's leading hard-goods retailer offering customers the convenience of three "stores" under one roof - automotive, sports and leisure, and home products. 

Amazing Results:

Through employee leadership and involvement, CTC implemented: 

• a full 6S Lean Program comprised of:
   Scanning, Sorting, Simplifying, Sweeping, Standardizing, and Sustaining

• a Lean Strategy Map

 

"OTI helped us get started down the road of continuous improvement. We didn't know where to start, but OTI recommended 6S as a logical first step. They helped us train our management team and staff in 6S methodologies and processes, and guided us through the early phase of the 6S results.

Since that time, we are deploying full Lean methodologies and experiencing significant productivity gains as a result of the tools we learned through OTI. I am confident that OTI's professionalism and knowledge was critical to helping our staff gain acceptance of 6S at such an early stage."

Len Foster
Divisional V.P. for Toronto Distribution Operations
Canadian Tire Corporation Ltd.

 

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