Customer Success Story: Sporting Goods
Business Issue: Warehouse Inefficiencies, Delayed Order Processing
This case study outlines LEGACY’s work with a leading sporting goods company. They have sold over 100 million units of their core product. In recent years, they have expanded their offerings considerably, offering many complimentary products within their field. Nearly 2 million units are manufactured each year, with an average of 3,000 units made each day at their main facility. During peak production time, the factory increases production to approximately 5,000 units per day.
West coast distribution operation unable to meet demand in small parcel processing area during peak season. Warehouse inefficiencies manifested challenges such as:
The client needed an immediate solution to restore small parcel processing to current processing.
LEGACY came in with an immediate response: a two-day focused support of lean platform leaders with a Lean Action Workout (AWO). During this Lean AWO, LEGACY:
Value and Results:
As a result of the Lean AWO, there was an 85.74% improved maximum capacity rate of small parcel processing at peak production.
In addition to these improvements, the workout session also identified significant opportunities for future improvements in footprint utilization and overprocessing.
“We were proud to help our client improve shipment processing by over 80% during peak season and exceed service expectation goals.”
–LEGACY Lean and Quality Team
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