The Challenge
A mid-size manufacturing client faced rising operational costs and production bottlenecks across three facilities, resulting in a 23% efficiency gap versus industry benchmarks.
Our Solution
Metamorph deployed a Lean Six Sigma engagement over 12 weeks, conducting value-stream mapping, eliminating seven categories of waste, and redesigning shift handover protocols.
Results
- 18% reduction in operational costs within 90 days
- Production throughput increased by 31%
- Employee-led continuous improvement culture established