When PULL Replaces PUSH: Proven Results

The results summarized below are from clients I have helped go from PUSH to PULL. While these projects varied greatly in scope and product, each of them were completed in about 3 months and delivered near-immediate results. The Military organization used a forecast every 4-6 months to determine min/max inventory levels. The other two companies used a monthly forecast process. The cut & sew company had made significant investments in the prior 5 years to improve forecast accuracy.

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Cut and Sew Products from Asia Suppliers

  • 50% reduction in manufacturing lead-times
  • 40% percent reduction in total inventory at wholesaler and manufacturing
  • $400K per year expense reduction
  • 30% increase in capacity
  • Significantly less effort to manage

PVC Building Products for Regional Wholesalers and Big Box Retailers

  • 100% on-time delivery up from 85%
  • 10% reduction in inventory
  • 50% reduction in manufacturing lead-times
  • Eliminated expedites
  • Eliminated overtime (skilled workers were quitting due to constant forced overtime)
  • Substantial increase in net profit

Military Helicopter Repair and Overhaul

  • 50-80% reduction in repair and overhaul lead-times
  • Less inventory
  • Eliminated overtime
  • Expedites reduced from 40-50 % to less than 10%
  • Follow up Lean projects where highly focused to continue improvements