Case studies
Change is real when the work changes.
A closer look at the operational problems, practical interventions, and results IBS has helped organizations pursue.
High-SKU Manufacturing Facility
Folder-Gluer Changeover Reduction
Challenge
A high-SKU-mix environment was crippling folder-gluer productivity with long, inconsistent changeovers. Setup practices varied wildly by shift, undermining daily output targets and eroding schedule reliability.
What IBS did
IBS deployed a comprehensive SMED analysis to separate internal and external setup tasks, standardized critical settings for rails, belts, and glue systems, and developed visual setup guides by SKU family with hands-on operator training.
- 30-40% reduction in changeover time
- Increased daily line availability
- Improved schedule adherence
Annual Savings: $150,000-$200,000 | Payback: <5 months | ROI: 2.2x
Multi-Line Production Facility
Compressed Air Leak Prevention
Challenge
Undetected air leaks and unstable pressure caused cycle variation, tooling failures, and excessive energy consumption across a 12-line configuration.
What IBS did
Full ultrasonic leak audit with tag tracking, pressure/flow sensors at each line, upgraded air dryers with dew point monitoring, and PM integration.
- 14% reduction in energy costs
- 60+ compressor trips eliminated annually
- 120 hours/year of unplanned downtime eliminated
Annual Savings: $270,000 | Payback: ~6.2 months | ROI: 1.93x
Manufacturing Operations Team
Leader Standard Work & Tiered Management
Challenge
Leaders spent most of their time firefighting with no structured escalation process and limited visibility into execution gaps across shifts.
What IBS did
Defined role-specific Leader Standard Work, designed SQDCP-aligned tier boards, established management cadences, and coached leaders during live execution.
- Faster issue identification and resolution
- Improved plan-vs-actual performance
- Cultural shift toward accountability
Annual Savings: $140,000 | Payback: <6 months | ROI: 1.6x
Industrial Manufacturing Plant
Maintenance Planning & Reliability Improvement
Challenge
Reactive maintenance dominated operations with routinely deferred preventive work, leading to frequent unplanned stoppages.
What IBS did
Reviewed maintenance backlog and failure history, standardized PM routines, aligned priorities with production needs, and established downtime tracking with root cause reviews.
- 18% reduction in unplanned downtime
- Improved asset availability
- Better maintenance/production coordination
Annual Savings: $210,000 | Payback: ~7 months | ROI: 1.5x
Manufacturing & Distribution Company
Business Process Optimization, Order to Production
Challenge
Late engineering changes, incomplete work orders, and material availability issues created delays, rework, and expediting costs.
What IBS did
Mapped end-to-end order-to-production process, identified handoff gaps and bottlenecks, clarified ownership, and implemented governance controls.
- Improved schedule stability
- Reduced expediting and rework
- Faster customer response
Annual Savings: $160,000 | Payback: ~6 months | ROI: 1.6x
Fortune 500 Industrial Group
Global Manufacturing Optimization
Challenge
Persistent production bottlenecks and rising operational costs across three continents.
What IBS did
Implementation of a standardized Operational Excellence framework and Value Stream Management.
- 22% reduction in global lead times
- $14M annual cost savings through waste elimination
- Standardized processes across 12 manufacturing sites
Leading Tech Hardware Manufacturer
Supply Chain Resilience Transformation
Challenge
Vulnerability to market volatility and logistics disruptions.
What IBS did
End-to-end supply chain redesign with advanced risk evaluation and buffer optimization.
- 35% improvement in supply chain responsiveness
- Zero production stops during major regional disruptions
- Improved inventory turnover by 18%
Regional Healthcare Provider
Strategic Culture Realignment
Challenge
Low employee engagement and stagnant patient satisfaction scores.
What IBS did
Executive coaching and leadership development focused on a culture of continuous improvement.
- 40% increase in staff engagement scores
- Top-decile patient satisfaction ranking achieved in 18 months
- 25% reduction in administrative overhead
Your operation
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Talk with us about the work, the people closest to it, and where a practical change could begin.