A Few Success Stories
At ROI Consulting LLC, we provide comprehensive solutions backed by our team of experienced professionals. We foster collaboration and innovation to ensure we not only understand the core needs of clients, but also help them develop successfully. Read our success stories below.
Maximizing Material Handling
A customer came to us seeking ways to cut their internal material handling expenses. Aware of their inefficiencies but lacking the resources to devise an optimized solution, we utilized a software simulation of their current process alongside a proposed lean alternative, targeting a cost reduction exceeding $300,000 annually. In the fiercely competitive manufacturing sector, efficiency is paramount. Firms are perpetually on the hunt for methods to refine their processes, enhance productivity, and minimize waste.
Increasing Production Output
With a closed-circuit camera system, we were able to improve visibility in some of the blind spots of a customer's assembly lines. This allowed the line leader to see stoppages before they affected the output of line, resulting in better efficiency. Additionally, we were able to use Theory of Constraints methods and team adjustments to further improve the customer's operations.
Strategic Decoupling
During an assembly line output analysis, we identified that the process lacked the stability required to reliably support one-piece flow at the target takt time.
To improve performance, we strategically decoupled key sections of the line and introduced monitored buffer locations to absorb minor interruptions and reduce the impact of short-term losses.
The result was increased overall output and a practical roadmap to reduce buffer inventory over time through focused problem solving and continued process improvement.
Optimizing Shopfloor Layouts
When a customer needed to add new equipment and reconfigure production processes, we developed a new AutoCAD layout to maximize existing floor space, improve workflow, and integrate AMR material deliveries.
After the layout was approved, we provided hands-on project support by managing equipment installation and startup, helping the customer move from planning to successful implementation with minimal disruption.
Ramping Up AMR Deliveries
After purchasing Agilox and Rexroth AMRs, the customer needed hands-on support to increase utilization and improve the return on their investment.
We learned the software, developed an expanded automated delivery system, and installed the required hardware to support higher AMR usage across the operation.
The result was a doubling of automated deliveries and the elimination of thousands of manual Kanban deliveries.
5S After Relocation
When a customer relocated assembly lines to a new facility, their internal resources were fully focused on startup and meeting customer production requirements.
We provided short-term operational support by leading 5S activities and reviewing the Kanban system to align in-house material deliveries with the new production strategy.
This gave the customer experienced, hands-on support during a temporary increase in workload and helped improve organization, material flow, and startup readiness.