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TOM INGRAM AND ASSOCIATES, INC.

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Health Beauty & Cosmetics Manufacturers: 

Operations Improvement Success Stories

 

(79)$2 Million+ Savings in 60 Days on Product Damage in Shipping

  • Secured Regular Orders from Major Customers, Resulting in Regular Manufacturing Schedule In Just a Few Months

  • Major Reduction in Product Damage During Shipping

  • 20% Reduction in Cost of Order Processing in Just a Few Months

  • Expanded program with similar results to dozens of additional customers and additional divisions

Category:  Near-HBC, (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(79)

 

(75)$300 Million Cost Savings Year 1

  • Another $300 Million Savings in Year 2

  • 25% improvement in production line up-time in just a few weeks. 

  • Lead to 10 Years of Effective Acquisitions and Improved Profits

  • Dramatic Reduction In Capital Spending

  • 67% output increase from a non-competitive plant in 2003.  On target for additional 60 percent improvement in 2004. 

  • 20% production improvement in certain plants instead of 2 to 4% improvements, which were best ever achieved previously

  • 40% Sustained Improvement In 10+ Plants

  • Attitude on capital spending has changed. When improvement is needed,instead of thinking about new capital investment, company gets better results from the  existing investment through 100 day improvement projects

  • Sustained improvement from 55% plant utilization to 70%. Lower results no longer tolerated

Category:  HBC, Specialty Paper  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(75)

 

(78)Supplier Helps Colgate Become #1 in Toothpaste Market Share

  • Manufacturing Capacity Doubled in Four Months

  • $2 Million Cost Savings in Shipping, Delivery Time Reduced

Category:  HBC  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(78)

 

(81)Improved Plant Output 17% in 6 Weeks

  • Improved On-Time Shipping from 80% to 95%, Sustained Improvement

  • Avoided $2 Million Capital Expenditure

  • Avoided $2 million capital expenditure on new system

Category:  Near-HBC  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(81)

 

(73)IT Business Projects Now Pay For Themselves In One Year

  • FDA Submission Time Reduced by 6 Months+

  • Submission Backlog Reduced from 80,000 Pages to 10,000 Pages and Sustained, Despite Doubling of Work Load

  • All Accomplished in a Few Months in U.S.

  • Results duplicated in U.K.

  • Improved quality of data submissions and reduced time needed to scrub and recheck data

  • Submission forms backlog reduced from 80,000 pages to 10,000 pages in three months

  • Submission form backlog maintained at 10,000 pages despite doubling of work load

Category:  HBC  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(73)

 

(76)$400 Million Profit Improvement Through Series of 100 Day Projects

  • Effective Merger Under Difficult Circumstances

  • 10% Sales Gain With Top 30 Customers in a Few Months

  • $400 million in incremental profits (On track to actually achieve as of this writing)

  • Reduced machine downtime for maintenance from two weeks to one week

  • $285,000 in annual savings within 100 days through consolidated purchasing and contract renegotiation

  • Consolidated two data centers into one within four months.

  • Completed full merger integration planning within 12 weeks. Enabling implementation to start immediately after close of the merger

Category:  HBC, Specialty Paper  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(76)

 

(77)Reduced Quality Assurance Audit Time by over 30% within 100 days. 

  • Duplicated Common System in Three Major Acquisitions

  • In the following two years, successfully integrated the clinical quality assurance functions of three additional major acquisitions.

Category:  HBC  (RHSA)

Details:  http://www.tomingraminc.com/HBCMfrsIncreaseSalesReduceCosts.htm#(77)

 

(3)CASE STUDY: Freed Up 63,000 Sales and Support Hours Per Year, Cost Reduction, Solid Processes and Execution: 

  • Associate led effort for one of the three largest merchandising organizations in the U.S. 

  • Resulted in $2.5 million per year in labor savings, a nation-wide set of standard processes and removal of 250,000 potential errors per year. 

Category:  Headquarter Call, Merchandising Process Improvement  (TI)

Details. No31cSalesProcessImprovementSuccessStoryShortV2.pdf 

 

 

 Additional Operations Improvement Successes

Item

Success Story Numbers

SKU Count Reduction

(50)

Fixtures

(39)

Information Technology

(73), (529), (522), (502), (506), (509), (518), (514), (525), (504), (542), (543), (528), (520), (539), (533), (505), (510), (530), (507)

Plant Output Improvement, Cost Savings

(76), (78), (81)

New Product Development, R&D

(73), (77)

Common Systems with New Acquisitions, Around the World

(3), (77), (79)

Shipping, Delivery

(81), (79), (78)

Customer Service

(3), (79),

Collections

(79), (506)

 

 

 
   

 

*  Success stories, client quotes and payback estimates are provided as general illustrations of past performance and represent summaries of long term, complex efforts.  They are often used to teach concepts and lessons learned, and may have been simplified considerably.  Estimates of financial impact are estimates only, and not intended to convey exact financial information.  Some have been altered to protect confidential information.  We ask that prospective clients contact our references and request specific details of relevant success stories prior to any decision to use our services.