All case studies
Manufacturing (Car Wash Equipment)
$1.6M+ in Savings Across a Multi-Year Operational Overhaul
Over a four-year relationship the client brought us back for engagement after engagement — manufacturing, field service, warehouse footprint, and the MRP system itself — because each one paid for itself.
Client: Car Wash Equipment Manufacturer · name withheld
$1.6M+
Total annualized savings delivered
-35%
Field service overtime
13+
Warehouses consolidated
Situation
- Overhead costs were elevated with no clear, data-backed path to reduce them.
- Field service labor and overtime were running well above budget with no staffing model tied to workload.
- A footprint of 13+ warehouse locations carried redundant cost with no consolidation plan.
- The legacy MRP system had been abandoned in practice — teams ran shadow spreadsheets and fought daily fires instead.
Approach
- Conducted a full overhead cost analysis and identified over $600K in reducible cost.
- Restructured management layers, cutting positions from 19 to 12.
- Rebuilt the field service labor model, driving a net 6-position reduction and a full overtime overhaul.
- Revitalized the MRP system, eliminating shadow tracking and reactive scheduling.
- Executed a warehouse consolidation program spanning 13+ locations.
Results
- $600K+ in annualized overhead cost reduction.
- $530K in annualized manufacturing direct-area savings.
- $420K in annualized field service labor savings, including a net 6-position reduction.
- 35% reduction in field service overtime — $469K in annualized savings.
- $201K in annualized savings from 13+ warehouse closures and relocations.
- Management structure streamlined from 19 to 12 positions.
- MRP system revitalized, eliminating shadow systems and daily fire-fighting.
Ready to put this kind of rigor to work in your business?
Every engagement starts with a conversation about what's actually broken and what would move the number.