Case Study 1
Case Study 2
PROJECT: Banta Healthcare Group (BHG)
Optimize Operations team lead by: David L. Gurbach, President
ISSUES
• Supply Chain
• International Product Line Startup
• Product Line Expansion
• Team Organization and Management
• Good Manufacturing Practices (GMP)
OPTIMIZE OPERATIONS SOLUTION
BHG was the single source supplier to Zeiss Corporation of microscope drapes, a Class 2 medical device. Annual sales exceeded $5 million with very attractive margins. Extreme pricing pressure from an offshore source resulted in a need to transition the manufacturing and production of the product to a lower cost platform. Banta Corporation’s Mexico JV partner, Grupo Imagan, although primarily a printing company, managed a small healthcare business located in Mexico City and was identified as a possible future source for the product. A management decision was made to transfer the existing production cell from its Wisconsin location to Mexico City. The team quickly responded and successfully transitioned the product platform to Mexico within six months, and moved the device through FDA approval within a 12-month timeframe.
This decisive and proactive approach enabled the business unit to maintain the very high-profile Zeiss business, meet the customer’s pricing targets and maintain an attractive level of profitability for BHG stakeholders.
DELIVERABLES
1) Transparent product quality and performance
2) Lower cost margin and profit protection
3) FDA approval (fast tracked)
4) Maintain Zeiss account
PROJECT: A global $45 million Tier I metal fabricator in the automotive, heavy truck, construction, agriculture, motorcycle, and general industrial markets
Optimize Operations team lead by:
David L. Gurbach, President
OPERATIONS ISSUES
• International Plant Startup
• Supply Chain
• Project Management and Implementation
• Quality Programs (ISO/TS/APQP/TQM)
• Key Account Management
OPTIMIZE OPERATIONS SOLUTION
Mercury Products Corporation, a $40 million Tier I metal fabrication supplier to the heavy truck (Class 8), automotive, construction and agriculture heavy equipment markets was requested by large OEMs (Daimler Truck, PACCAR, Navistar, Volvo) to establish a manufacturing presence in Mexico to support expansion initiatives.
DELIVERABLES
A site was selected in the Monterrey-Saltillo area to support manufacturing and supply chain expansion. Within a 12-month timeframe the following deliverables were achieved:
1) MPC Productos de Mexico was incorporated and established.
2) A 70,000-square foot manufacturing plant was constructed.
3) Equipment and technology were transferred from Schaumburg, Illinois to the Monterrey location.
4) Key managers and plant workforce were hired, trained and qualified.
5) A labor union was selected and a contract was signed.
6) Certification from all major OEMs was received.
7) Supply chain was address with identification and qualification of a local supplier base.
8) ISO certification was approved and TS16949 certification was initiated.