Multi-Million Dollar Stainless Steel Foundry

• Supplier in launch, new product, new technology
• Significant monthly losses
• Not process capable (900-1,000 per week), low first-time quality (0-5%), high scrap (35%), high manual labor processes

• Interim management replaced existing management
• Re-engineered plant floor layout, added automation, brought core production in house, problem constraint isolation

• First-time quality improvement to 85%, reduced headcount by 40% and improved throughput to 6,600/week
• Generated positive cash flow