From Firefighting Chaos to Controlled Operations: Rapid Productivity Gains Across Manufacturing & Warehouse
Operations Implementing operating discipline, supervisory capability, and management
flow & systems to stabilize performance and unlock productivity
This story is for CEOs who
- Are dealing with immature and unstable manufacturing operations and constant firefighting
- Face inefficiencies and rising costs that make them noncompetitive in the marketplace
- Lack visibility into productivity, downtime, and labor effectiveness
- Have supervisors promoted without formal training or operating standards
- Struggle with overtime misuse, temporary labor control, and workforce planning
- Need fast track digital tools into manufacturing operations to build sustainable operating disciplines
The Challenge
Manufacturing and warehouse operations were operating with limited structure and minimal performance
visibility. Supervisors had received little or no formal training, and there was no consistent management
operating system to control daily execution.
The operation lacked reliable OEE and downtime tracking, had no formal overtime control process, and
no labor planning tied to workload. Warehouse layout and flow were inefficient, production items were not
pre-marshalled, and maintenance controls were absent. Planning and scheduling were largely reactive.
Baseline TVO maturity was below Level 1, reflecting limited standard work, inconsistent accountability, and
high variability across shifts.
Maine Pointe:
- Production and warehouse planning boards to stabilize daily execution
- Short-interval control boards and supervisor training
- Standardized shift startup procedures and guidelines
- Formal overtime control systems and procedures
- Daily and weekly performance reviews with root-cause analysis
- Daily resource planning and labor ordering tools aligned to workload
- Line planning standards supporting line selection, sequencing, and crew planning
- Improved controls to stabilize schedules and improve adherence
- Warehouse flow improvements and pre-marshalling of production items
- Digital performance tracking for real-time OEE and downtime visibility\
- Bespoke supervisor training on the fundamentals of supervision
- Fully documented processes, procedures, and training materials
The Results
- 16% direct productivity improvement achieved against baseline in an 8-week sprint
- $3.8M in annualized productivity savings realized in 8 weeks
- Roadmap established to deliver $10–$11M in annualized productivity savings
- $7.3M+ (15%) in savings delivered in 10 weeks using an accelerated target pricing approach
- 15% reduction in direct warehouse crewing through improved flow and labor planning
- More than 10% reduction in spoilage through improved inventory control and stock rotation
- Real-time OEE and downtime visibility enabled through digital performance tracking
- Improved schedule adherence and operational stability
- TVO maturity increased from below Level 1 to Level 2, with a clear path to Level 3
- All processes, procedures, and training documented and handed over