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Case Studies

Review of Best Practices in Product Development; Common Pitfalls using PM Software to Manage Projects; and Stage Gate Product Development Process

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Best Practices in Product Development

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Our Clients

New Product Development

  • Developed a NPD Phase Gate system for a multiple billion dollar division of a Fortune 200 manufacturing company, resulting stage gate process incorporated APQP quality process, roles & responsibilities & risk assessment tools. This division NPD process was adopted as a corporate wide process.
     
  • Developed an NPD stage gate process trained employees NPD & MS Project for a Fortune 300 plastic packaging company. Trained over 600 employees in New Product Development and MS Project scheduling; implemented a NPD stage gate process that won a company wide award; and numerous NPD projects showed resultant success - a $4 million capital investment project was on time and 20% under budget.
     
  • Developed a NPD phase gate process for the NA division of a publicly held French automotive polymer company.

Program Management & Enterprise Project Management

  • Developed project schedule template for German manufacturer of design & build automation equipment. The company project templates allowed new & senior project managers to create complete project schedules in days instead of weeks with a 1% major milestone date accuracy.
     
  • Developed a project schedule & resource planning project system for a US privately held company with four plants. Design & build scheduling system allowed project managers and resource managers to plan plant manpower and machine utilization on a nine month planning horizon. The sales department every week to “sell into” overloaded or under loaded plant loads with appropriate market pricing- thus increasing thru put,, decreasing premium overtime and subcontract costs and avoiding lengthy periods of low burden absorption.
     
  • Developed a project plan with schedules & resource manning in MS Project for a $10 million capital investment global new produce development project for a billion dollar division of a Fortune 200 automotive supplier. The NPD project was launched on time in 31 months - significant time to market reduction from the 42 to 60 months for historical projects of similar size.
     
  • Implementation of a project scheduling phase of an enterprise project management system at an Automotive OEM Tool & Die Plant.

Plant Turnarounds

  • Turnaround manufacturing consulting to a US privately held tool company. A strategic consulting analysis with a “manufacturing due diligence” allowed metric based decision by the owner to purchase the manufacturing tool company with a bank presentation of the turnaround manufacturing strategy. Implemented two major projects; consolidation of two manufacturing ERP systems into one system; and a contractual/legal environmental exit to meet the conditions of the buy-sell agreement.
     
  • Planning system for a privately held Austrian R&D equipment company.
     
  • Managed the NA manufacturing engineering, materials, manufacturing plant for a privately held Austrian R&D equipment company. Grew the product line business from $6 million to $12 million annual sales and the gross profit from (2%) to 12% of sales, will improving on time delivery and manufacturing productivity.

ERP Projects

  • Implemented of a successful ERP system for the NA division of a privately held Austrian R&D equipment company. Installed an ERP system which replaced five other systems MRP, A/P, A/R, Project Management system with no major business system interruption/problems after Go Live.

Special Projects

  • Developed a change order addendum quotation system for a Japanese CNC machine tool company. The quotation system allowed the company to submit and gain approval on two addendums to a $15 million contract resulting in $1.2 million additional pricing.
     
  • Project manager to complete aged incomplete and aged projects for special machine design & build contracts for a German design & build special machine company. The formal project management allowed the closure and collection of $5.5 millions aged accounts receivable in a five month period and substantial recovery of customer project satisfaction.

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