The Situation
Capacity existed on paper but was trapped by long lead times, setup loss, and uneven labor deployment.
Growth appeared capex-bound, though the true limit was execution from order to shipment.
Revenue was constrained by how the plant ran, not by what it could theoretically produce.
What We Did
We focused on increasing sellable output from installed capacity.
- Redesigned production flow to shorten lead time.
- Improved changeovers to recover productive hours.
- Optimized workforce deployment against actual workload.
The Results
Revenue increased 40%, productivity improved, and operating cost reduced from the same rolling setup.
A larger share of installed capacity now reaches customers where value is realized.
Strategic Takeaway
- Before adding capex, quantify how much current capacity reaches the customer.
- Many growth constraints are execution constraints in disguise.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
Connect with our consulting team to discuss your current operational challenge and the outcomes you want to achieve.
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