From Bottlenecks to Breakthroughs
Updated
Customer: WSI Broussard
- Set-up time cost reduction
- 97%
- Inspection wait cost reduction
- 93%
- Machine-hours recovered
- ~187
- Monthly capacity unlocked
- $28,000+
- Capital investment required
- None
Ask us how our customer regained $28,000 in lost opportunity.
Overview
Within nine months, a machine shop in Louisiana—under new leadership—converted Auredia insights into direct operational gains. By targeting two primary constraints, the team:
- Reduced set-up time by approximately 97%
- Reduced inspection-related wait time by approximately 93%
- Recovered ~187 machine-hours
- Unlocked over $28,000 in monthly production capacity
- Achieved these outcomes with zero capital investment
The Challenge
Despite having years of production data available, WSI Broussard faced persistent slowdowns due to:
- Prolonged machine set-up times
- Extended wait periods for inspection clearance
These inefficiencies were difficult to isolate and resolve without clear visibility or tactical frameworks.
The Solution
A combination of Auredia analytics and frontline-driven execution made rapid, lasting improvements possible:
- Hotspot Mapping via Auredia Dashboards: Auredia’s Trends and Opportunity Cost dashboards highlighted hidden bottlenecks in real-time.
- Kaizen Blitzes: Focused, operator-led improvement workshops (“Kaizen”) addressed root causes immediately and sustainably.
Critically, data visibility empowered the team to act quickly—while leadership ensured changes held.
The Results
Set-Up Time
- Peak: $18,900 across 124.88 hours
- Current: $556.85 across 3.00 hours
- ↓ 97.05% cost reduction
- 121.88 machine-hours restored
- $18,343.15 in monthly opportunity cost eliminated
Waiting on Inspection
- Peak: $10,536.30 across 70.68 hours
- Current: $763.35 across 5.51 hours
- ↓ 92.76% cost reduction
- 65.17 machine-hours restored
- $9,772.95 in monthly opportunity cost eliminated
Why It Worked
- Transparent data enabled immediate action
- Auredia exposed constraints previously overlooked
- Leadership support made the changes sustainable
- Operator involvement drove on-the-ground execution
*Kaizen: Rapid, operator-led improvement workshop. Small, targeted actions—big operational results.
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