Team Project Summaries

Product Portfolio and Supply Chain Optimization

Company: 
3M
Industry: 
Diversified Manufacturing
Solution: 
Strategic Assessment
Abstract: 

The team worked with 3M’s Construction and Home Improvement Markets (CHIM) Division evaluate root causes to improve protective eyewear products. The team identified opportunities to improve service, reduce inventory costs, improve product mix, improve supply chain efficiency, and standardize supply chain decision making process.

PDF icon PDF download (57.86 KB)

Identifying Opportunities for the Seller Experience

Company: 
Amazon - Fullfillment by Amazon
Industry: 
High-Tech/Electronics
Solution: 
Lean Analysis, Process Improvement, Strategic Assessment
Abstract: 

The Tauber team performed an in-depth study of the complex supply chain to identify opportunities for internal improvements that can be applied to the Seller reimbursement policies.

PDF icon PDF download (49.85 KB)

Amazon Robotics Stow Error Reduction

Company: 
Amazon - Operations
Industry: 
High-Tech/Electronics
Solution: 
Inventory Management, Lean Analysis, Logistics, Process Improvement
Abstract: 

The Tauber team identified significant inputs to slow error introduction leading to an annual cost savings projected at $1.6M at TPA1 alone and $14.4M across the Amazon Robotics Sortable Network.

PDF icon PDF download (51.93 KB)

Scaling Flow Surface Preparation and Growing the Market for Ultra-High Pressure Waterjets

Company: 
American Industrial Partners - Flow Surface Preparation
Industry: 
Diversified Manufacturing
Solution: 
Lean Analysis, Process Improvement, Strategic Assessment
Abstract: 

The Tauber team created a detailed path for the company to better attach and expand the addressable market for water-based surface preparation addressing the company's goal to grow from $35MM to $70MM over the next 2-3 years through organic growth and acquisition.

PDF icon PDF download (1.32 MB)

Market Entry Strategy for High Pressure Hydraulic Fracturing Fluid Ends

Company: 
American Industrial Partners - Serva Group
Industry: 
Diversified Manufacturing
Solution: 
Lean Analysis, Logistics, Process Improvement, Procurement and Purchasing, Services, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team created a business plan for growing the fluid end and component business to $100 million a year in revenue by benchmarking current competitors and their corresponding product offerings, developing a competitive business model, and formulating a go-to-market strategy around the optimum sales, service, and supply chain for Serva.

PDF icon PDF download (60.8 KB)

Strategic Assessment of Food Industry Applications to Waterjet Technologies

Company: 
American Industrial Partners - SHAPE
Industry: 
Food and Beverage
Solution: 
Strategic Assessment, Technological Assessment

Optimizing Information Flow in a Composite Smart Factory

Company: 
Boeing - 777X
Industry: 
Aerospace
Solution: 
Information Technology, Inventory Management, Strategic Assessment
Abstract: 

The Tauber team developed an “Operations Dashboard” concept that helps key stakeholders make quick decisions and predict problems before they arise, thus reducing cycle time at key bottleneck processes by 20%, eliminating the need to purchase additional manufacturing capacity, and projecting to save over half million dollars per year increasing an additional capacity of 10,000 engineering hours for value-added projects.

PDF icon PDF download (49.65 KB)

Carbon Fiber Recycling Strategy to Achieve Zero Waste-to-Landfill

Company: 
Boeing - BCA Product Development
Industry: 
Aerospace
Solution: 
Inventory Management, Lean Analysis, Logistics, Process Improvement, Supply Chain
Abstract: 

The Tauber team successfully created and piloted a plan to enable the new 777X Composite Wing Center to become a zero waste-to-landfill production facility. 

PDF icon PDF download (623.77 KB)

Enabling a Low Cost & Scalable Component Repair Supply Chain

Company: 
Boeing - CAS
Industry: 
Aerospace
Solution: 
Logistics, Supply Chain
Abstract: 

The Tauber team successfully designed and piloted a new systematic R&O approach focusing on a single Gold Care 787 part.

PDF icon PDF download (54.1 KB)

BDS 777X Paint Process Optimization

Company: 
Boeing - Defense, Space, and Security
Industry: 
Aerospace
Solution: 
Lean Analysis, Process Improvement, Strategic Assessment, Technological Assessment
Abstract: 

The Tauber team conducted in-depth business-case analysis leading to saving Boeing $22.4M over the fist five years of implementation.

PDF icon PDF download (141.14 KB)

Strategic Evaluation of the Pipacicaba Foundry

Company: 
BorgWarner - Emissions Brazil
Industry: 
Automotive
Solution: 
Logistics, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team's deliverables included measured cost & technical competitiveness, improved factory utilization, reviewed alternatives and recommended direction for the longer term strategy, and manufacturing competitiveness for the future.

PDF icon PDF download (49.7 KB)

Global Inventory Management

Company: 
BorgWarner - Morse Systems
Industry: 
Automotive
Solution: 
Inventory Management, Lean Analysis, Process Improvement, Supply Chain
Abstract: 

The Tauber team deliverables include: map out the inventory value chain at each location, benchmark driving factors of inventory turns & identify root causes of high stock level at each location, derive an optimum inventory turn and supply chain costs for identified RU, and recommend a forward path to achieve the optimized turn including inventory Upstream Supply Chain and Downstream to OEM customer.

PDF icon PDF download (61.72 KB)

Strategies for Dramatic Inventory Turn Improvement at a Newly Acquired Plant

Company: 
BorgWarner Emissions - Germany
Industry: 
Automotive
Solution: 
Inventory Management, Lean Analysis, Logistics, Process Improvement, Supply Chain
Abstract: 

The Tauber team developed an optimal logistics strategy for plants in Oberboihingen, Germany and Oroszlany, Hungary, identified the floor space and inventory value needs of the logistics strategy, developed an implementation plan for the logistics strategy, and began implementation in trial areas.

PDF icon PDF download (75.2 KB)

Reducing Time to Commercialize Existing Products on New Applications

Company: 
Borgwarner Thermal Systems
Industry: 
Automotive
Abstract: 

The BorgWarner Thermal team proposed a solution to accelerate the time to commercialize existing products on new applications to customers. The team identifed the best practices from 5 technical centers and recommend a global standardized process for application engineering.

PDF icon PDF download (61.28 KB)

Strategic Insourceing of Maintenance, Repair, and Operations Inventory

Company: 
BorgWarner Transmissions Systems
Industry: 
Automotive
Solution: 
Logistics, Supply Chain
Abstract: 

The Tauber team developed a course of action for the insourcing of MRO material procurement and management at two plants to reduce costs and improve operations. The team cleansed and migrated MRO data to the BorgWarner SAP system, create and map procedures for all inventory management processes, test the processes in SAP, and establish new vendors to handle the MRO demand previously met by the third-party.

PDF icon PDF download (58.09 KB)

Preventing the Mixing of Small Parts

Company: 
BorgWarner Turbo Systems
Industry: 
Automotive
Solution: 
Manufacturing, Quality Improvement
Abstract: 

The Tauber team proposed a global solution to control material flow of similar, small components to prevent quality defects.  The team created a cost-efficient implementation strategy to be deployed across Turbo System’s 10 production facilities, resulting in 100% control and traceability of components and saved up to $10.61 million annually.

PDF icon PDF download (852.17 KB)

Expanding Service Offerings at Optifreight Logistics

Company: 
Cardinal Health
Industry: 
Healthcare
Solution: 
Logistics, Supply Chain
Abstract: 

The Tauber team assessed the market trends, customer pain points and evaluated the service needs of the target customers, and developed a comprehensive service model that offers value added and cost effective solutions.

PDF icon PDF download (51.04 KB)

Exploring Innovation in the Factory Through 3D Printing

Company: 
Cisco
Industry: 
High-Tech/Electronics
Solution: 
Logistics, Strategic Assessment, Supply Chain, Technological Assessment
Abstract: 

The Tauber team developed a strategy for how Cisco can incorporate the disruptive technology of additive manufacturing into its design and manufacturing processes. The benefits are projected to save $4M in capital expenses annually.

PDF icon PDF download (51.42 KB)

Reduce Rework and Increase Efficiency in End-to-End Commercialization Process

Company: 
ConAgra Foods
Industry: 
Food and Beverage
Solution: 
Lean Analysis, Logistics, New Product Development, Process Improvement, Supply Chain
Abstract: 

The Tauber team completed a value-stream map of the end-to-end commercialization process.

PDF icon PDF download (57.03 KB)

Reducing Energy Costs for Residents of Michigan

Company: 
DTE Energy
Industry: 
Energy
Solution: 
Lean Analysis, Process Improvement, Strategic Assessment, Sustainability, Technological Assessment
Abstract: 

The Tauber team developed a Value Stream Map of the fuel process with Pareto Analysis of issues causing high overall process costs due to fuel prices or unit efficiency; developed a project plan for recommendations, including a cost estimated implementation timeline; implemented changes when appropriate while developing final recommendations; and reported detailing current state findings and future state recommendations with ROI’s and timelines for major projects.

PDF icon PDF download (51.67 KB)

Simulation of Material Handling Operations for Labor Requirements Calculation

Company: 
Ford Motor Company
Industry: 
Automotive
Solution: 
Information Technology, Inventory Management, Lean Analysis, Process Improvement
Abstract: 

The Tauber team studied the material handling operation inside a final assembly shop to identify block and starve conditions. The use of simulation could capture the stochastic nature of the manufacturing system supporting an accurate calculation and allocation of labor resources that could lead to $1.6 million in potential savings.

PDF icon PDF download (672.51 KB)

Corporate Desruption Through Utilization of Additive Manufacturing in the NPI Cycle and the Resulting Impact on GE Aviation's Business Model

Company: 
GE Aviation
Industry: 
Aerospace
Solution: 
Lean Analysis, New Product Development, Process Improvement, Strategic Assessment
Abstract: 

The Tauber team re-mapped the design and development process with an objective to deliver more differentiated product to the market sooner under a cost constrained environment. This included supply chain plant level business plans and engineering organization strategies and execution plans to target and realize the greatest opportunities within the shortest timeline.

PDF icon PDF download (59.92 KB)

The Final Countdown: Aligning Supply and Demand for a Better Build Out

Company: 
General Motors - Global Purchasing and Supply Chain
Industry: 
Automotive
Solution: 
Logistics, Supply Chain
Abstract: 

The Tauber team analyzed the historic market ordering trends on the Cadillac SRX to reduce options and associated part complexity and subsequently material obsolescence cost at the end of the model build out. They formulated a model to repeat this process to capture savings for future model build outs projected to save GM $15.4M annually across its supply chain.

PDF icon PDF download (63.55 KB)

Restructuring the Value Chain for North America Commercial Markets

Company: 
Guardian Industries - Fabrication
Industry: 
Diversified Manufacturing
Solution: 
Lean Analysis, Logistics, Process Improvement, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team developed a current state mapping of value stream highlighting largest constraints; developed an “unconstrained” model to understand the value of finding solutions to barriers identified; finalized output prioritizing implementation of the proposed solutions, bridging current state to a best in class model. They included estimated values of success through potential range of outcomes, key drivers to the success or failure of the project, and associated risk mitigation strategy to improve likelihood of success upon implementation.

PDF icon PDF download (59.31 KB)

Internal Logistics Optimization or Guardian Glass

Company: 
Guardian Industries - Supply Chain
Industry: 
Diversified Manufacturing
Solution: 
Inventory Management, Lean Analysis, Logistics, Process Improvement, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team provided a solution for identifying and replicating the best practices in the warehouse and distribution network for Guardian flat glass division. The solution also provided a data driven objective methodology for Guardian to select and prioritize its capital investment over the next 3-5 years.

PDF icon PDF download (49.6 KB)

Creating Capacity Visibility to Say Yes to New Business

Company: 
Kostal of America
Industry: 
Diversified Manufacturing
Solution: 
Inventory Management, Logistics, Procurement and Purchasing, Supply Chain
Abstract: 

The Tauber team developed a capacity planning solution, providing visibility on current and future capacity of plants to Kostal business teams.

PDF icon PDF download (390.03 KB)

Pricing Strategies for an Infrastructure-As-A-Service Cloud Market

Company: 
Microsoft Cloud
Industry: 
High-Tech/Electronics
Solution: 
Information Technology, Lean Analysis, Process Improvement, Strategic Assessment
Abstract: 

The Tauber team conducted a thorough mapping of the current value stream for the Microsoft Azure service, particularly as it pertains to the Compute and Storage units; future state mapping of the value stream, with an emphasis on optimizing for real-time feedback on datacenter capacity and efficient and repeatable processes for instant price changes on the Azure commerce platform; and included a financial understanding of the implications of such price changes.

PDF icon PDF download (49.77 KB)

Increasing Sales Promotion Efficacy for Worldwide Markets

Company: 
Microsoft Surface
Industry: 
High-Tech/Electronics
Solution: 
Inventory Management, Lean Analysis, Logistics, New Product Development, Process Improvement, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team created a customer heatmap for special pricing and offers (including ROI, Incremental Unit Volume, and Gap Analysis); Prioritized/De-Prioritized decision matrix to help drive decisions on investment; mapped a customer decision map on purchase preference; and created an idea generation on unique go to market offers (opex bundle (financing hardware with bundled software, etc.). Expected incremental revenue for the Surface Commercial channel is approximately $18.3M per year.

PDF icon PDF download (51.49 KB)

Corrosion Integration Into SGO

Company: 
Pacific Gas & Electric Company
Industry: 
Energy
Solution: 
Lean Analysis, Process Improvement, Strategic Assessment, Sustainability
Abstract: 

The Tauber team evaluated gaps, bottlenecks, cycle time, and compliance issues within the processes described in the "Super Gas Operations" initiative, based on resolving issues in their work management, resource management, and close-out of work processes. From these findings, they focused on the Corrosion Prevention and Correction process. The team identified solutions to address these gaps, pilot the solution, and deliver sustainable improvement across the Corrosion work process.

PDF icon PDF download (1.2 MB)

Infrastructure Capacity Analysis and Optimization

Company: 
PepsiCo
Industry: 
Food and Beverage, Retail
Solution: 
Inventory Management, Logistics, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team built a model to calculate costs related to insufficient storage space. The team performed comprehensive analysis of existing infrastructure capacity modeling process that enabled the team to identify gaps in existing capacity modeling. Collectively the cost module and improved infrastructure capacity planning process can reduce PepsiCo operational costs by $18.4 million.

PDF icon PDF download (167.99 KB)

Next-Gen Clinical Supply Forecasting Solution

Company: 
Pfizer Inc.
Industry: 
Pharmaceutical
Solution: 
Information Technology, Lean Analysis, Logistics, Process Improvement, Supply Chain
Abstract: 

The Tauber team benchmarked the current state and a competitor's forecasting process followed by a comparative analysis of different vendor forecasting tools. The cost savings for 2 clinical trials evaluated as case studies were estimated to be approximately $2.4M and $5.8M respectively. In once case study, the savings were approximately $9.6M if the options were capable of being implemented from the start of the study.

PDF icon PDF download (53.33 KB)

Development of Separables Fitting Quoting System

Company: 
Precision Castparts Corporation
Industry: 
Diversified Manufacturing
Solution: 
Lean Analysis, Logistics, Process Improvement, Strategic Assessment, Supply Chain
Abstract: 

The Tauber team standardized and automated the price quoting process by integrating the operational, financial, and marketing data required for pricing into one quoting system through which pricing policies could be established, refined, and implemented based on changing costs, market forces, and available production capacity. Immediate annualize savings were $1 million.

PDF icon PDF download (60.83 KB)

Optimization Through Process-Focused Manufacturing

Company: 
Raytheon
Industry: 
Aerospace
Solution: 
Inventory Management, Lean Analysis, Logistics, Process Improvement, Supply Chain, Sustainability, Technological Assessment
Abstract: 

The Raytheon Tauber team was tasked with coming up with a framework to transform a product-focused factory into a process-focused factory, in which space would be organized based on process flow.

PDF icon PDF download (49.46 KB)

MEASURING PACKAGE-CARE IN THE UPS SHIPPING ENVIRONMENT

Company: 
UPS
Industry: 
Logistics and 3PL
Solution: 
Process Improvement, Strategic Assessment
Abstract: 

The Tauber team developed the Package Environment Evaluation Tool which measures acceleration, and static and dynamic compression in the package environment and conducted a financial analysis. The recommendation to increase the performance of the below average performance facilities to average levels could result in a net savings of $5.5M per year.

PDF icon PDF download (159.58 KB)

Stepping outside the Box with Big Data

Company: 
Verizon Wireless
Industry: 
Retail
Solution: 
Logistics, Strategic Assessment, Supply Chain, Sustainability
Abstract: 

The objective of this project was to improve sustainability and efficiency in Verizon Wireless’ Supply Chain. Specifically, the Tauber Team worked to improve carton design and fill efficiency across the supply chain’s forward distribution network.

PDF icon PDF download (51.12 KB)

Refrigeration Cabinet Foam Process Modeling

Company: 
Whirlpool Corporation
Industry: 
Diversified Manufacturing, Retail
Solution: 
Information Technology, Lean Analysis
Abstract: 

By analyzing timing data, changeover data, and production scheduling data at each line, as well as receiving input from plant employees, engineers, and facility computer programmers, the Tauber team created several future state models for each area.

PDF icon PDF download (834.47 KB)

Increasing Profits Through Diversifying Revenue Streams

Company: 
Youth for Understanding
Industry: 
Other
Solution: 
Lean Analysis, Process Improvement
Abstract: 

Tauber conducted a benchmarking analysis of YFU USA’s main competitors to better understand the nonprofit’s space in the intercultural exchange industry competitive landscape and develop a long-term strategy for revenue diversification.

Read about Youth for Understanding here.

PDF icon PDF download (51.71 KB)