Case Studies
Details of Some of Our Successful
Case Study #1
10,000 sq ft Startup Warehouse
National Distribution Center in SW Ontario
Lean Kaizen Project
Results
Highlights:
Complete Warehouse transformation from what the company described as,
“A Complete Mess” to “A Well Oiled Machine” in only 2 Months12 Successful Lean Kaizen Improvements Completed in only 2 months
780% ROI at Today’s Kaizen Hero Consulting Rates
$635,000 Net Profits per year from Improvements
$2,000,000 of Product Inventory 100% Audited for Quality, Quantity & SKU Accuracy
10% Increase in New Business Sales
Additional Benefits
Project Completed in 6 weeks, 2x Faster than Estimated by Owners
600% Increase in Order Pick Speed from Well-Organized Inventory
100% Warehouse Inventory Accuracy with Daily Cycle Counts
100% Accurate Order Completion
99% Reduction in Back orders & Lost Opportunities
99% Increase of Same Day Order Completion
92% Inventory Quantity Accuracy Improvement
75% Less Customer Service Issues
65% Accuracy Improvement of Physical vs WMS Inventory
5S & Daily Inventory Cycle Counts Implemented
Significant Increase in Teamwork, Morale & Cooperation
Problematic & Expensive Low ROI Machinery Removed
Business Saved from Sales/Closure
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Case Study #2
National Distribution Center in SW Ontario
40,000 sq ft Food & Non-Food
Lean Kaizen Project
Results
Highlights:
18 Successful Low-Cost, High ROI, Lean Kaizen Improvements Completed in only 6 Months
896% ROI at Today’s Kaizen Hero Consulting Rates
$11,000,000 Total Yearly Increase in Net Profits
$7,200,000 Net Profits per year from Improvements
$3,800,000 in New Business Sales
30% Increased Company Growth (From Initial 3%)
Distribution Center Doubled in Size to 80,000 sq ft.
New Material Handling Equipment (MHE) Purchased
Additional Benefits
36,000 Hours in Non-Value Added Operations time Eliminated
$14,000 Increased Yearly Bonuses for each of the 100 Employees
88% Reduction in Overtime
81% Reduction in Damages/Lost Inventory, Pick & Pack Errors, Re-Shipped Products and Return to Stock
55% Reduction in Customer Service Issues
Significant Increase in Teamwork, Morale and Cooperation
Lean Kaizen Training Supported and Sustained all Improvements
New Employees Hired & Trained in Lean Kaizen Concepts
Business Saved from Sales/Closure
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