Kessler was losing money on its highest-volume line and couldn't say why. Three previous cost programmes had taken out overhead without touching the line itself, because nobody could produce a costing anyone trusted below plant level.
We rebuilt product-level costing from the shop floor up over five weeks — on shift, across all four plants. Two SKUs turned out to consume 40% of changeover time for 3% of volume; both were killed. Three supply contracts the procurement team had been told were fixed were reopened and renegotiated. The board's condition throughout was that no site closed, and none did.
"They found the loss in week two. It took us three years not to." Group Operations Director, Kessler Industrial
We spent the first three weeks in the data room before going to the floor. On a plant problem that sequence is backwards, and it cost the engagement most of a month.