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An Eye for Operational Excellence

To accommodate a growing pipeline of goods, a consumer products company needed to add capacity to its manufacturing network of more than 40 sites in 20 countries. An operational excellence program, combined with rigorous training, increased capacity and led to millions in cost savings.

Successful product development had led this consumer goods company to expand its production capacity at dozens of sites around the world. Its goal was clear: build capability for the future while identifying and delivering business value that was consistent with its overall strategy.

The company worked with BCG to create an operational excellence program as part of an overall transformation. It included plant network strategy, opex/lean, and external supply optimization. Deployed to more than 20 of the company’s sites over 18 months, the program became embedded in the company’s culture due to its focus on both behavioral and technical value levers.

More than 150 full-time employees were involved, all of whom developed new problem-solving skills. The company also increased technical capabilities through operational excellence tools and approaches.

Today, the project is on pace to deliver $100 million in savings—up to ten times the return on investment. The company is also enjoying improved returns compared to its competitors.

Lean & Manufacturing
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