Efficiencies in Product Development and Manufacturing

Client Overview

A leading R&D and manufacturing facility with over 20 pilot and demonstration plants manufactures and certifies a diverse range of products. The facility is also engaged in product development and testing.

man in a lab coat examines a microscope, focused on his research in a laboratory setting

Challenge

The organization faced challenges in meeting rising project demands, including a surge in supported projects and developed products. Excessively long project durations on pilot and demonstration units caused delays to new programs. Quality Control bottlenecks emerged as excessive material sampling overwhelmed analytical testing teams, leading to program deliverable delays, inefficiencies, and increased manpower costs.

Objectives

  • Streamline workflows and establish processing and testing criteria for products under-development

  • Optimize pilot and demonstration unit operation and scheduling 

  • Enhancing resource utilization to increase project throughput without additional capital investment

Results

  • increase icon

    increase in number of projects supported

    25%

  • cost icon

    average cost savings per project

    20%

  • cost saving icon

    cost saving related to unit operation and product testing

    $1.3M

  • Reduced cycle time for pilot/demo operations, minimizing lost opportunities and backlog.

  • Optimized QC workload, balancing required testing without excessive sampling.

  • Faster project turnaround allowed projects to meet deliverable timelines, improving reliability and stakeholder confidence.

  • Efficient resource allocation increased project capacity, allowing more programs to be executed annually.

  • Enhanced overall operational agility, positioning the company for sustained innovation and growth.

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