Flat Cable Technology Manufacturer Diagnostic Assesment
Driving Flow, Productivity, and EBITDA Growth
Challenge
Inefficient material flow, excessive WIP, and lack of visual management or standardized systems limited productivity, consistency, and collaboration across operations.
- Excessive WIP and long lead times due to poor material flow and multiple handoffs.
- Limited visual management and minimal Lean adoption, making abnormalities hard to identify.
- Reliance on on-the-job training without formalized work instructions, impacting consistency.
- Lack of a structured daily management system, clear KPIs, and performance tracking.
- Functional silos between manufacturing, QA, and engineering, reducing cross-team collaboration.
Solution
Delta Driver performed a full diagnostic assessment, built a Lean roadmap, and implemented model cells, KPIs, 5S, and daily management systems to drive control and flow. Conducted a comprehensive diagnostic assessment to identify throughput, quality, and scalability opportunities. Built a Lean transformation roadmap focused on productivity, flow, and operational control:
- Designed model product cells to reduce handoffs from eight to three and cut part travel from 656 ft to ~20 ft.
- Introduced visual management systems including SQDC boards, KPI dashboards, and real-time performance tracking.
- Implemented progressive 5S to improve workplace organization, safety, and flow visibility.
- Developed standardized work instructions and training programs to improve operator consistency and onboarding.
- Established a tiered daily management system (MDI) with leader standard work, collaborative problem-solving, and clear accountability.
Results
Unlocked $500K–$1.2M in EBITDA potential, reduced lead times by up to 40%, and positioned the company for scalable, data-driven growth and improved margins.
- Identified $500K–$1.2M in annual EBITDA improvement potential through Lean-driven productivity, reduced lead times, and WIP optimization.
- Provided pathway to reduce lead times by up to 40% and improved throughput using model product cells.
- Outlined needed visual controls and KPIs to make performance and issues transparent in real time.
- Positioned the company for scalable growth, improved margins, and enhanced operational resilience.
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