MANUFACTURING

CASE STUDY
Industry Rubber
Location Missouri
Year 2015 - Present
PROJECT RESULTS

20% annual revenue growth with 50% reduction in average workload for the owners while improving product quality and increasing margins.

SITUATION

A family owned manufacturer of rubber and plastic products since 1994, known to its customers for their production quality and knowledge, struggling to maintain their standard of excellence as they grow

CHALLENGES

Work instructions and previous run data were kept on paper and difficult to access

Data insights and measurements were missing or time-consuming to produce

Job scheduling conflicts were preventing on time deliveries

Staff was experiencing overlapping tasks and unclear goals and deliverables

The four software programs for ordering, vendor interaction, receiving and shipping, usage and production were not integrated

SOLUTIONS
  • Implemented JobBOSS with custom built modules
  • Built a cloud based web application to generate estimates and quotes tied into real time data Customized their ERP system by building a process SPC job quality control system that captures current data and displays historic data.
  • Automated quoting production directly into instantly generated editable Word documents and PDFs
  • Created a drag-and-drop scheduling tool that helped visualize the shop schedule live based on actual production speeds
  • Calculated supplies and raw material requirements dynamically based on scheduled work to provide insights to the shop floor
  • Implemented Search Engine and Social Media Marketing

SCRAP RATE WAS DECREASED BY 7% TO <1%

(a savings of $57K per year, 2% of revenue or 11% of materials)

NON-CONFORMANCE RATE WAS REDUCED BY 82%,

resulting in higher confidence of quality for customers

QUOTE TURNOVER TIME WAS LOWERED BY 70%

by completely eliminating non-quote related work such as formatting, text editing, and retyping

LABOR EFFICENCY INCREASED BY 7%

INCREASED SITE TRAFFIC AND BUSINESS EXPOSURE

PROVIDED 2X ROI FOR AD SPEND

TRAFFIC RESULTED IN AN ADDITIONAL 20 NEW LEADS PER MONTH.