{"id":20333,"date":"2025-03-07T18:56:34","date_gmt":"2025-03-07T18:56:34","guid":{"rendered":"https:\/\/plgconsulting.com\/?p=20333"},"modified":"2025-03-07T18:56:53","modified_gmt":"2025-03-07T18:56:53","slug":"fortune-200-manufacturer-achieves-400-efficiency-gain-through-automation-consulting","status":"publish","type":"post","link":"https:\/\/plgconsulting.com\/fortune-200-manufacturer-achieves-400-efficiency-gain-through-automation-consulting\/","title":{"rendered":"Fortune 200 Manufacturer Achieves 400% Efficiency Gain Through Automation Consulting"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"20333\" class=\"elementor elementor-20333\" data-elementor-post-type=\"post\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-523887e elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"523887e\" data-element_type=\"section\">\r\n\t\t\r\n\t\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\r\n\t\t\t\t\t\t\t\t\t\t\t<div class=\"elementor-column elementor-col-33 elementor-top-column elementor-element elementor-element-ce9546c\" data-id=\"ce9546c\" data-element_type=\"column\">\r\n\t\t\t\t\t<div class=\"elementor-widget-wrap\">\r\n\t\t\t\t\t\t\t\t\t<\/div>\r\n\t\t\t\t<\/div>\r\n\t\t\t\t<div class=\"elementor-column elementor-col-33 elementor-top-column elementor-element elementor-element-f123610\" data-id=\"f123610\" data-element_type=\"column\">\r\n\t\t\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\r\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-3260fa53 elementor-widget elementor-widget-text-editor\" data-id=\"3260fa53\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>A ~$10B global business unit for a Fortune 200 company producing and selling productivity and protective equipment was unable to meet demand (backlog up 750%, mostly in North America) during COVID-19. The processes for manufacturing masks were very manual and costly. Hiring new operators was difficult, with a high turnover.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7c5eb11 elementor-widget elementor-widget-heading\" data-id=\"7c5eb11\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Services Provided<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ceec855 elementor-widget elementor-widget-text-editor\" data-id=\"ceec855\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-size: 10.5pt;line-height: 115%;font-family: Montserrat\">Working collaboratively with the client, the team:\u00a0<\/span><\/p><ol><li>Enabled the business strategy using capacity planning and cost analysis.<\/li><li>Optimized the manual processes to reduce costs by increasing capacity.<\/li><li>Designed and implemented three automated sites that increased capacity and reduced the number of required resources.<\/li><li>Closed two manual facilities and reallocated work to automated sites.<\/li><li>Designed and launched a semi-automated site for surgical masks.<\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-047f9b9 elementor-widget elementor-widget-heading\" data-id=\"047f9b9\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Results<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-073c4d7 elementor-widget elementor-widget-text-editor\" data-id=\"073c4d7\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p class=\"whitespace-pre-wrap\"><span style=\"font-size: 10.5pt;font-family: Montserrat;color: white\"><span style=\"color: #000000\">The client realized a 400% efficiency gain and doubled capacity.\u00a0<\/span><\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-26e573b elementor-icon-list--layout-traditional elementor-list-item-link-full_width elementor-widget elementor-widget-icon-list\" data-id=\"26e573b\" data-element_type=\"widget\" data-widget_type=\"icon-list.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<ul class=\"elementor-icon-list-items\">\n\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-chevron-right\"><\/i>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">The automated sites required three FTEs to run a manufacturing cell versus the manual cell needing 20+ FTEs.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-chevron-right\"><\/i>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Semi-automated site went from 0 to 4 million masks produced daily in less than six months.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-chevron-right\"><\/i>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Reduced the number of late orders to zero.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-chevron-right\"><\/i>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Realized 40% sales growth.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-chevron-right\"><\/i>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">The sites were set up in an accelerated timeline to support the demand during COVID.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\r\n\t\t\t\t<\/div>\r\n\t\t\t\t<div class=\"elementor-column elementor-col-33 elementor-top-column elementor-element elementor-element-4d08625\" data-id=\"4d08625\" data-element_type=\"column\">\r\n\t\t\t\t\t<div class=\"elementor-widget-wrap\">\r\n\t\t\t\t\t\t\t\t\t<\/div>\r\n\t\t\t\t<\/div>\r\n\t\t\t\t\t<\/div>\r\n\t\t\t\t<\/section>\r\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>A ~$10B global business unit for a Fortune 200 company producing and selling productivity and protective equipment was unable to meet demand (backlog up 750%, mostly in North America) during COVID-19. The processes for manufacturing masks were very manual and costly. Hiring new operators was difficult, with a high turnover. Services Provided Working collaboratively with [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":20335,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"mc4wp_mailchimp_campaign":[],"footnotes":""},"categories":[37],"tags":[245,246,244],"class_list":["post-20333","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-study","tag-automation","tag-covid-19","tag-facility-automation"],"acf":[],"featured_image_src":{"landsacpe":["https:\/\/plgconsulting.com\/wp-content\/uploads\/2025\/03\/N95-MASK-1080x445.png",1080,445,true],"list":["https:\/\/plgconsulting.com\/wp-content\/uploads\/2025\/03\/N95-MASK-463x348.png",463,348,true],"medium":["https:\/\/plgconsulting.com\/wp-content\/uploads\/2025\/03\/N95-MASK-300x300.png",300,300,true],"full":["https:\/\/plgconsulting.com\/wp-content\/uploads\/2025\/03\/N95-MASK.png",1080,1080,false]},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - 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