savings delivered in 10 months representing 8% of COGS for major US Medical Device Manufacturer

Project & Details

US Medical Device Disposables Manufacturing site for a top 20 Medical Device company

Immediate need for cost savings across key product value chain due to increasing competition.

Deep down analysis of end-to-end value chain from raw material suppliers to delivering finished goods to end customer including data breakdown, opportunity identification & prioritization, forming right team, execution and project close-out with lessons learned.

Tools & Technology

  • Procurement Excellence & Category Management – Resins, Molded Components, Extruded tubes & films, Packaging, Sterilization, Transportation optimization
  • Make vs. Buy
  • Operating Efficiency Improvement – OEE , Risk-based quality sampling, Reliability-centered Maintenance Excellence, Lean flow, Span-of-control analysis
  • Cultural & Accountability – KPI deployment & Communication Cadence, Reaction plans, Quality Awareness, Celebrating Success


  • USD$3.6M annualized savings representing 8% of value stream COGS with 10 months for complete implementation
  • ROI – 8 months’ pay back period
  • 40% reduction in non-conformances
  • OEE Improvement from 50% to 72%

Customer Testimonial

Never seen a consulting firm so good at execution.