This engagement focused on shifting the organization from reactive problem-solving to a disciplined continuous improvement mindset. Through leadership coaching, quality system redesign, and hands-on Kaizen facilitation, the company stabilized operations and unlocked meaningful performance gains.
Margin Expansion
Improved Overall Equipment Effectiveness (OEE) from 40%
Warehouse Space Freed
A prominent packaging company serving the food and beverage and industrial markets for more than 25 years was experiencing operational challenges that were limiting growth. Leadership initially identified rising levels of unplanned downtime as the primary concern, but further investigation revealed deeper issues.
High scrap rates and material write-offs were common, often driven by quality failures that did not meet customer standards. These challenges pointed to gaps in quality systems, leadership practices, and problem-solving capability across the organization. Adonis Partners was engaged to help address these issues and build a more sustainable continuous improvement mindset.
Adonis Partners began with a comprehensive four-day International Organization for Standardization (ISO) mock audit. The assessment revealed that the existing quality program was structured primarily to pass audits rather than improve product quality. The program was reoriented to focus on quality outcomes while remaining compliant with ISO requirements.
To improve operational efficiency and leadership effectiveness, Adonis facilitated leadership training for supervisors across all departments. Quality staff and leaders were trained on statistical methods to establish product specifications and update them based on customer feedback.
Adonis also conducted on-site Kaizen Facilitator training for 12 leaders and role-modeled Kaizen event facilitation. Training and application focused on three critical operational areas: injection molding changeovers, sheet changes in thermoforming, and the quality control sampling and testing process.
The coaching and improvement initiatives delivered significant performance gains. Overall Equipment Effectiveness (OEE) improved from 40 percent to consistently above 60 percent, resulting in more than $2.5 million in margin expansion. Inventory aging analysis and 5S implementation freed up 20 percent of warehouse space.
Daily departmental huddle boards improved communication, strengthened shift hand-offs, and reinforced accountability. Together, these changes stabilized operations, embedded continuous improvement behaviors, and positioned the organization for sustained growth.
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Packaging Company
✓ Conducted kaizen facilitator training for 12 key leaders
✓ Rendered over $2.5M in margin expansion
✓ Installed a flow of communication and tracking between departments