Project
Portfolio
CLIENT
CASE STUDY 1
Client:
ADP
Location: New York, NY
Edgewood, NY
Randolph, MA
Industry:
Print and Fulfillment of Client Statements and Communications
Project Accomplishments:
• Consolidated
3 large fulfillment centers into one large Center of Excellence
• Designed efficient print operations for high speed Print / Letter Shop
to improve workflow and expand throughput
• Specified and implemented new Auto ID system using WMS and Bar Code Technology,
resulting in significant labor savings in recording and documenting information
• Designed ‘state-of-the-art’ Print Center in Downtown NY to
serve the brokerage community in multi-floor operation using automated Material
Handling equipment to transport product effectively across 4 floors
• Implemented new Distribution Center technology to reduce overall area
requirements by over 35% and increase picking efficiency by 15% through VNA technology
CLIENT
CASE STUDY 2
Client:
Inmet / Multimatic
Location: Ontario, Canada
Industry:
Automotive
Project Accomplishments:
• Simulated docking operation for current and future receipts and shipments
to determine facility viability
• Optimized delivery, arrival and shipment times by reducing waiting times
20 to 50 % throughout an 18-hour window
• Improved docking decisions and assignments to allow Inmet extended occupancy
within the facility in rapidly growing operation
• Recommended improvements for loading, unloading and processing time at
the dock to speed operations and increase dock throughput
 CLIENT
CASE STUDY 3
Client:
VIASYS Healthcare
Location: Orange County, CA
Madison, WI
Palm Springs, CA
Industry:
Medical Device
Project Accomplishments:
• Implemented Lean Manufacturing in 3 business locations over 12 to 18
months, including specially designed training programs
• Improved inventory on-hand through implementation of Pull techniques
• Reduced ECO cycle times by 85% and manufacturing labor by over 20% with
Kaizen events
• Conducted Lean Sigma Pilot Line development and implementation in 4 manufacturing
sites across 3 divisions
• Led self-directed work teams through cost improvement programs, resulting
in savings of over $1.5M in initial 6 months
• Planned and designed new Pilot Manufacturing line
• Conducted Master Plan for consolidation into new manufacturing facility
in Ireland
CLIENT
CASE STUDY 4
Client:
Zappos.com
Location: Shepherdsville, KY
Industry:
Retail Internet Shoe Distributor
Project Accomplishments:
• Designed improved Material Handling systems in current DC to increase
capacity and reduce cost per pair handling to meet business growth of 75% unit
growth per year
• Performed analysis of picking alternatives including Carousel and VNA
systems leading to increased pick productivity of over 50%
• Designed new Automated Distribution Center to allow for growth in activity
(up to 300%) over the next 4 to 6 years
• Performed detailed ROI on all aspects of material handling systems
• Conducted detailed transition analysis leading to improved strategy that
minimized late shipments and physical relocation costs
• Developed specification for WCS software system and assisted in selection
of approved vendor
CLIENT CASE STUDY 5
Client:
Milton CAT (Caterpillar)
Location: Milford, MA
Industry:
Parts Distribution – Heavy Industrial
Project Accomplishments:
• Designed new Distribution Center to issue parts to service community
and customers for local repairs
• Developed detailed specifications for WMS and WCS interface
• Developed equipment specifications for all Material Handling and Material
Storage systems in DC
• Developed detailed ROI analysis on all equipment purchases and achieved
cost payback of under 2 years
• Documented improved procedures and methods for new D C
• Project managed smooth implementation of WMS technology and material
handling equipment
CLIENT CASE STUDY 6
Client:
The Holmes Group, Inc.
Rival Division
Location: Milford, MA
El Paso, TX
Fremont, CA
Sedalia and Clinton, MO
Industry:
Retail Distribution – Consumer Kitchen / Home Electronics
Project Accomplishments:
• Detailed consolidation project occurring over a 3-year implementation
to reduce the number of Distribution Centers from 17 to 3
• Reduced inventory by over $40M through implementation of improved planning
tools and Pull technology
• Identified programs to reduce operational costs by over 35% through improvement
projects over the past 3 years
• Designed 3 Distribution Centers totaling over 1.4M sf
• Designed Parts Repair depot with improved Material Handling systems to
speed orders to customers by using 40% less labor
 CLIENT
CASE STUDY 7
Client:
Tiffany & Co.
Location: Cumberland, RI
Parsippany, NJ
Industry:
Jewelry – Manufacturing and Distribution
Project Accomplishments:
• Designed new Automated Distribution Center to significantly improve order
turn time and cost/unit for distribution
• Designed and implemented new Material Handling system and Automated Picking
systems totaling over $20M, including AS/RS system
• Project Managed entire site implementation, including all procurement
activities of Manufacturing and Distribution related equipment
• Detailed design of new Jewelry manufacturing operation using ‘state-of-the-art’ equipment
and Lean Principles
CLIENT
CASE STUDY 8
Client:
CYTYC Corporation
Location: Marlborough, MA
Industry:
Medical Device Manufacturing
Project Accomplishments:
• Master Planning of new Manufacturing facility to expand current capabilities
and consolidate multi-floor operation into a single floor
• Detailed implementation of Lean Manufacturing program into work cells
to reduce quality issues and improve cycle time
• Detailed implementation of State-of-the-Art manufacturing facility including
procurement of equipment and transition planning coordination
• Execution of smooth product line transfer without any production loss
CLIENT
CASE STUDY 9
Client:
Boston Scientific Corporation
Location: Miami, FL
Spencer, IN
Quincy, MA
Santa Rosa, CA
Costa Rica
Industry:
Medical Device Manufacturing
Project Accomplishments:
• Master Planning of new Stent Manufacturing facility to smooth workflow,
reduce Cost of Goods manufactured and expand current capabilities
• Integrated design to increase overall flexibility
• Reduced operational cost of facilities resulting in savings of $250k
to $750k per facility
• Developed Center of Excellence strategy across multiple sites to allow
for rational product line transfers across multiple facilities
CLIENT
CASE STUDY 10
Client:
General Electric – Panametrics Division
Location: Waltham, MA
Industry: High Tech / Electronics Manufacturing
Project
Accomplishments:
• Implementation of Lean manufacturing across the entire division, including
training, piloting and implementation coaching
• Lean Sigma implementation in multiple work cells resulting in department
savings up to 50% labor costs, 80% WIP and 40% spatial
• Master planning of new State-of-the-Art manufacturing center allowing
the streamlining of process and equipment
• Detailed design of new work process, layout and ROI justification
• WIP reduction of over $2M throughout entire plant
CLIENT
CASE STUDY 11
Client:
General Dynamics
Location: Deland, FL
Industry: Defense Manufacturing
Project
Accomplishments:
• Lean Audit and analysis of existing facility with recommendations to
support a reduction in space from 420k sf to 125k sf
• Detailed planning of new Manufacturing facility to promote higher volumes
and streamline workflow
• Lean implementation of Pilot Work cell
• Interfaced with Design / Build contractor throughout construction and
transition
• Smooth transition and start up planning for new facility located 500
miles from current operation
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