From Bottlenecks to Breakthroughs

Ask us how our customer regained $28,000 in lost opportunity.

Overview

Within nine months, a machine shop in Louisiana—under new leadership—converted Auredia insights into direct operational gains. By targeting two primary constraints, the team:- Reduced set-up time by approximately 97%- Reduced inspection-related wait time by approximately 93%- Recovered ~187 machine-hours- Unlocked over $28,000 in monthly production capacity- Achieved these outcomes with zero capital investment

The Challenge

Despite having years of production data available, WSI Broussard faced persistent slowdowns due to:

- Prolonged machine set-up times

- Extended wait periods for inspection clearance. These inefficiencies were difficult to isolate and resolve without clear visibility or tactical frameworks.

The Solution

A combination of Auredia analytics and frontline-driven execution made rapid, lasting improvements possible:

- Hotspot Mapping via Auredia Dashboards: Auredia’s Trends and Opportunity Cost dashboards highlighted hidden bottlenecks in real-time.

- Kaizen Blitzes: Focused, operator-led improvement workshops (“Kaizen”) addressed root causes immediately and sustainably. Critically, data visibility empowered the team to act quickly—while leadership ensured changes held.

The Results

Set-Up Time- Peak: $18,900 across 124.88 hours

- Current: $556.85 across 3.00 hours- ↓ 97.05% cost reduction

- 121.88 machine-hours restored- $18,343.15 in monthly opportunity cost eliminated

 Waiting on Inspection- Peak: $10,536.30 across 70.68 hours

- Current: $763.35 across 5.51 hours- ↓ 92.76% cost reduction

- 65.17 machine-hours restored- $9,772.95 in monthly opportunity cost eliminated

Why It Worked

-Transparent data enabled immediate action- Auredia exposed constraints previously overlooked- Leadership support made the changes sustainable

- Operator involvement drove on-the-ground execution

*Kaizen: Rapid, operator-led improvement workshop. Small, targeted actions—big operational results.