Case Studies
Root Cause Analysis:
A company faced a 40% return rate on their prototype due to unresolved issues. I introduced a data collection and root cause analysis process, which reduced the return rate to 1% and saved $1M annually. This process resolved problems that had persisted for 4 years.
Re-Architecting a Prototype:
A company earning $2M/year with a prototype aimed to reach $20M. After re-architecting the system to a single board computer, they reduced build time from 6 hours to just 20 minutes. This new design not only made the product easier to maintain but also helped the company achieve its $20M goal while saving 5 hours in production per unit.
Compliance Testing:
A company was performing unnecessary product testing, costing $200K annually. After consulting the FAA and proposing a random testing schedule based on 10 years of data, they saved $200K in testing and $70K in technician salary, allowing the company to triple its growth with the same staff.
Quality Problems in Manufacturing:
An electronics company faced rework costs due to incorrect part footprints in its CAD system. By investing in a parts library built to JEDEC standards, the company sped up development times and eliminated costly rework.
We engaged Efficiency Edge to help us establish processes for our growing service business and are thrilled with the results. Chyle has the ability to ask the right questions and get to the heart of what needs improvement, and then he immediately begins to establish a framework for improvement. His suggestions and work are thoughtful and directly applicable—no theoretical frameworks that we have to adapt. I only wish we would have discovered him sooner!
DANA ANDERSON | President, Anderson Poolworks/Purewater Aquatics
Document Control System:
An aerospace company struggled with document management, leading to inefficiencies and extended FAA audits. After investing in document control software and a specialist, they streamlined processes and saved 60 work hours per week by organizing and mapping documents effectively.
Productivity:
Engineers were spending 40% of their time fixing manufacturing instructions. By hiring a dedicated document writer to create clear assembly and test instructions, the company restored 40% of engineering productivity, reducing errors and cutting costs.
A year into the implementation of the EOS operating system into our 10-person company, we were experiencing writers’ block documenting our core processes. Chyle put us back on track quickly and set us in a better direction than we would have been if we hadn’t gotten bogged down in the first place. It was a short engagement with long results, and we look forward to bringing him in more quickly if we get stuck in the future.
Owner – Professional Services Firm
Software Quality & Productivity:
A small company dealing with software bugs and delayed hardware implemented GIT for version control and Test Driven Development (TDD). This approach improved quality, reduced bugs by 75%, and saved 3 months of development time, allowing them to hit the market faster.
Hardware Verification:
A company averaging 7 board turns per design was spending $25K per turn, resulting in $1M/year in wasted resources. By implementing design review and test plan processes, the number of turns was reduced to 3, saving $1M/year and enabling the company to take on an additional project with a potential $10M revenue.
★★★★★
This would be a great spot for a testimonial from a past client.
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Compliance Cost Reduction:
A medium-sized company facing 15% yearly increases in compliance costs invested $170K in a safety compliance lab. This investment resulted in $300K annual savings, significantly reducing their compliance expenses.
New Test Methodology:
A company faced product returns and inventory issues due to ineffective testing processes. After leading a cross-functional team, the company replaced bed of nails fixtures with 5 flying probe machines, reducing product returns by 25% and freeing up space for an additional manufacturing line.
★★★★★
This would be a great spot for a testimonial from a past client.
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Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
Engineering Change Process Upgrade:
A company’s inefficient Engineering Change Order (ECO) process caused waste and communication breakdowns between engineering and manufacturing. After a Kaizen event led by a cross-functional team, they improved the process, resulting in $2M/year in operational savings.
★★★★★
This would be a great spot for a testimonial from a past client.
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.