Revolutionizing Modular Factory Productivity: A Data-Driven Approach

The Challenge: Uncovering Hidden Inefficiencies Across 24 Factories

A coalition of 24 independently-owned modular factories across the U.S. needed an in-depth evaluation of their labor productivity and process efficiency. With each factory operating under different conditions, leadership lacked clear visibility into where and how inefficiencies were impacting production.

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The Solution: Comprehensive Data Collection & Lean Analysis

Leveraging my expertise in Lean Six Sigma and process optimization, I conducted an extensive multi-factory assessment:

• 8+ factories audited, spending a full week in each facility.

• 400+ hours of direct production observation and 600+ hours of recorded factory work analyzed.

• 70+ employee interviews conducted to capture frontline insights.

Using this vast dataset, I applied Lean waste management principles to quantify value-added vs. non-value-added time across workflows. To enhance the accuracy and efficiency of analysis, I developed a proprietary software tool that streamlined data processing and performance calculations.

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The Results: A Game-Changing Discovery

• Identified a 100%+ improvement opportunity in labor productivity.

• Provided unprecedented quantitative insights into modular factory performance.

• Equipped factory leadership with a breakthrough process understanding to drive long-term productivity, throughput, and profitability gains.​

 

The Competitive Advantage: Data-Driven Process Optimization for Modular Factories

This project revealed hidden inefficiencies that had gone unnoticed for years, proving that deep operational analysis leads to transformative productivity gains.