Case Studies

“We have seen lasting results in the processes and procedures Lee help guide us through for our warehouse logistics.”
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Here is just a small sampling of how the Schwartz Profitability Group delivers results, helping clients improve operational efficiencies and successfully achieving their objectives.

Manufacturing Case Studies

Distribution Case Studies

Time to Upgrade? ERP Selection and Implementation

– International Skin Care Manufacturer

PROBLEM	Company is overwhelmed by spreadsheets, shackled by time-consuming inventory management systems and operational processes.
SOLUTION	SPG engaged to thoroughly assess existing operations and make recommendations. Comprehensive report strongly advises implementation of a fully functioning, integrated ERP/ MRP system.
RESULTS	SPG leads client through software selection. Implementation is due to begin shortly. (For more details . . .)

Daily Errors Eradicated in 3 Weeks –

International Manufacturer of Skin Care/ Home & Garden Products

PROBLEM	Recently installed software not working correctly per client, not being used properly per the VAR. Client is ready to scuttle the project after spending tens of thousands of dollars.
SOLUTION	After in-depth evaluation, garbage data trashed, then thoroughly updated. Software modifications implemented. Unproductive operational practices replaced with best practice procedures.
RESULTS	Within three weeks daily errors and work-flow disruption eradicated. Software working to everyone’s satisfaction. (For more details . . .)

Facility Consolidation. Make sense?

– International Electronics Manufacturer

PROBLEM	Forty miles separate two buildings used for inventory storage and assembly. New building is indentified to possibly consolidate operations. Pull the trigger?
SOLUTION	SPG engaged to conduct comprehensive Feasibility Study to evaluate storage space requirements projecting five years into the future.
RESULTS	Proposed building not sufficient to meet client needs. Study prevents client from making a damaging and expensive decision. (For more details . . .)

75% Growth – No Increase in Staff

– International Manufacturer

PROBLEM	Batch printing of nine-part shipping/ invoice forms. Wasting paper. Bottleneck of effort and activity.
SOLUTION	Placed separate printers on shop floor. Installed freight software. Upgraded accounting software. Integrated all systems.
RESULTS	Saved tens of thousands of dollars by eliminating five parts. Continuous flow of order fulfillment. Business grew 75% with no staff growth.

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Labor Costs Cut by 17%

– Multi-Location Specialty Distributor

PROBLEM	Poor on-time performance (60-70%) of receiving and shipping in multi-location environment.
SOLUTION	Implemented tighter operational controls and procedures. Established KPIs and benchmarking measurements.
RESULTS	On-time performance jumped over 95% in less than six weeks. Reduced temporary staffing by over 80%. Decreased total labor costs by approximately 17%.

Transportation Costs Cut by 30%

– International Hardware Company

PROBLEM	Outbound freight costs too high.
SOLUTION	Audited outbound activity and charges. Negotiated with carriers on behalf of client for better rates.
RESULTS	Client saved over 30% on outbound LTL (less than truckload) costs.

Doubled Output in 40% Less Time

– National Sporting Goods Distributor/ Retailer

PROBLEM	40,000 sq. ft. warehouse bursting at the seams. Paper based order picking systems requires days to complete with pallets stacked in almost every aisle.
SOLUTION	New distribution center purchased. SPG engaged to design the new warehouse plus implement a best-in-breed ERP/ WMS system. Procedures completely revamped.
RESULTS	Client went live in only 3-1/2 months, completely moved in with all systems go. Able to maintain pre-go-live staff levels while doubling output in 40% less time. Saved AT LEAST $200,000 in annual labor costs. (For more details . . .)

Inventory Sprouting Legs and Walking?

– Hand Tool Distributor

PROBLEM	Distributor believes the company is the victim of inventory theft.
SOLUTION	SPG conducts an intensive observation of warehouse practices and interviews staff. Theft not the issue. Indentifies need for new procedures and necessity for hiring more skilled management.
RESULTS	With SPG’s assistance, more qualified warehouse manager hired. Inventory management best practices are being implemented. (For more details . . .)

Poor Practices Impact Productivity

– Lighting and Energy Service Company

PROBLEM	Operational and sales procedures are highly inefficient. Processes are neither repeatable nor consistent. Ownership is convinced that poor practices are undermining opportunities and profitability.
SOLUTION	With contribution from client staff, SPG evaluates as-is state, identifies future-state procedures, then maps and thoroughly documents the steps necessary to achieve future-state processes.
RESULTS	Wasteful steps have been eliminated. Existing systems are better utilized. Documented procedures in place are efficient, repeatable and fully memorialized. (For more details . . .)

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