Revenue Generation Projects

Custom Window Frame Manufacturing Line Optimization Scope ONYX was engaged to analyze and optimize a frame assembly line consisting of manual cutting, CNC routing, and multi-step assembly processes. The client suffered from high rework rates, inconsistent outputs, and labor inefficiencies due to batch processing and tool misplacement. Key Results Increased Output: Improved throughput from 55 to 70 units per 10-hour shift with four fewer operators. Labor Savings: $200,000 in annual labor savings by reallocating staff post-efficiency gains.​ Cycle Time Reduction: 25% reduction in average cycle time through one-piece flow conversion and ergonomic workstation redesign.

Precision CNC Department Setup & Changeover Optimization Scope A precision machining client with 15 CNC machines faced inconsistent changeover times—ranging from hours to days—due to lack of standardization in fixturing and program retrieval. Key Results Setup Time Reduction: Decreased changeover time by 40% via modular workholding systems and centralized program libraries. Asset Utilization: Increased CNC utilization rate from 45% to 70%. Cost Avoidance: Avoided hiring 2 additional operators, saving approx. $120,000/year.

Production Line Time Studies & Bottleneck Removal Scope ONYX was asked to conduct time studies across a mixed-model production line experiencing frequent delays and line imbalances. Operators were frequently idle or overburdened. Key Results Line Balancing: Achieved 98% takt time alignment across stations. Waste Reduction: Identified and eliminated 3 major non-value-added tasks, reducing overtime by 30%. Profit Growth: Increased weekly production capacity by 15%, translating to ~$500,000 in additional annual capacity without expanding headcount.

Maintenance & Spare Parts Inventory Control System Scope The client experienced frequent downtime and part shortages across their production equipment due to lack of maintenance tracking and disorganized spare parts inventory. Key Results Downtime Reduction: Equipment uptime improved by 20% after implementing preventive maintenance triggers. Inventory Visibility: Tracked and reduced obsolete part spending by $18,000 annually. Process Digitization: Created a digital dashboard for maintenance and inventory monitoring.

Shipping Process Redesign & Fulfillment Optimization Scope ONYX was engaged to overhaul the shipping process of a manufacturing company facing major inefficiencies, labor waste, and quality issues. The original system required finished goods to be transported and sorted manually at the shipping department, involving up to 10 employees to locate, move, and load products—some weighing between 300–500 lbs. This created packaging damage, product misplacement, and significant safety hazards. ONYX designed and implemented a new shipping system that restructured the workflow upstream. Orders were cut and organized at the start of the line based on dealer and shipping method (state-based sequencing). Finished products were sorted directly into delivery-specific racks that required no rehandling, enabling a direct-to-truck loading process. Key Results Labor Savings: Eliminated the need for 20 manual handling positions, saving the company approximately $800,000/year. Quality Improvement: Reduced packaging damage due to minimal product handling, preserving product integrity and presentation. Efficiency Gains: Streamlined the shipping workflow, eliminating double handling and significantly reducing loading time. Customer Experience: Improved visibility on inbound racks allowed customers to plan for unloading, decreasing downtime on their end and reducing the number of personnel needed for offloading. Capital ROI: Though the project cost the company $1.2M, it generated $2.5M in annual savings, yielding a full return on investment within the first year. Timeline: Fully developed and launched in eight months from start to implementation.

Department Reallocation & Production Line Optimization Scope ONYX led a strategic relocation of an entire production department from one manufacturing plant to another in order to consolidate operations, improve efficiency, and reduce overhead. The project required detailed planning and coordination of the transport and setup of CNC equipment, as well as the procurement and commissioning of a new saw tailored to the receiving plant’s workflow. This move was designed not only to streamline production but also to right-size labor allocation and eliminate redundant roles across the plants. Key Results Labor Savings: The new layout and improved workflows enabled the removal of three operator positions, equating to $150,000 in annual labor savings. Efficiency Increase: Production efficiency on the restructured line improved by 30%, driven by optimized machine layout and streamlined material flow. Equipment ROI: The investment in a new saw enhanced cut accuracy, reduced rework, and improved throughput consistency. Cross-Plant Integration: Improved communication and scheduling between the two plants, with minimal disruption during the transition. Scalability: The updated configuration supports increased volume with fewer resources, positioning the line for future growth.

Enterprise Value Stream Mapping & Lead Time Reduction Scope ONYX was engaged to develop a comprehensive enterprise-level value stream map capturing the full workflow from order entry to final product delivery. The objective was to identify inefficiencies, redundant processes, and opportunities for lead time reduction across departments including order processing, planning, production, logistics, and customer fulfillment. After mapping and analyzing the flow of information and materials, ONYX led the company through a process redesign, streamlining workflows, automating redundant steps, and enhancing cross-functional coordination. Key Results Lead Time Reduction: The redesigned workflow eliminated process redundancies and gave back two full days of lead time, enabling faster order fulfillment. Monthly Profit Gains: The lead time recovery contributed to a revenue lift of approximately $300,000 per month, by enabling quicker turnaround, improved cash flow, and increased order capacity. Enterprise Visibility: ​ The value stream map provided executives with cross-departmental visibility, which exposed additional process gaps and improvement opportunities. Scalability: The process improvements supported scaling without expanding headcount, ensuring sustainable growth. Continuous Improvement Foundation: Created a foundation for future Kaizen events and Lean Six Sigma initiatives by standardizing and documenting enterprise workflows.

Saw Automation & Material Rework Reduction Scope ONYX led a project to reduce manual cutting errors and improve quality on a high-volume frame production line. The manual process required operators to calculate cut lengths by reading labels and inputting measurements—leading to frequent miscuts and rework. Approach Introduced a $25,000 automatic stop system at the saw station, network-integrated to automate cut list retrieval. Introduced a $25,000 automatic stop system at the saw station, network-integrated to automate cut list retrieval. Eliminated manual calculations and minimized operator interpretation errors. Results Service orders dropped from 30 per month to nearly zero, saving $55,000/month in rework. Recuts decreased from 60 to 20–30 monthly, improving material usage. Annual Savings: Approx. $1.32 million in material, labor, and rework costs. Improved safety and reduced downtime at the saw by eliminating human error.

Infeed Table Redesign for Quality Assurance & Cost Reduction Scope The objective was to develop a cost-effective, functional infeed table to ensure product functionality could be verified pre-packaging, improving quality control and production efficiency. Approach Optimized design concept for cost and performance through multiple iterations. Integrated innovative simulation techniques to replicate real-world door functionality, focusing on opening/closing accuracy. Developed a performance verification checklist to ensure every unit met alignment and operation standards. Results Reduced original table cost from $95,000 to $17,000 through thoughtful design revisions. Cut rework and service orders by 50% with improved product validation before packaging. Increased production throughput by 20%, resulting in a 15% increase in annual savings. Streamlined packaging station efficiency and reduced operator fatigue, elevating customer satisfaction through quality assurance.

Production Line Optimization Scope The goal was to fully optimize a hinged door manufacturing line by reducing waste, increasing throughput, and minimizing part mismanagement. The production line included saw, CNC, hardware, assembly, mocking, and glazing. Approach Conducted comprehensive time studies across stations to identify inefficiencies and bottlenecks. Transitioned to a one-piece flow, eliminating WIP racks and redesigning workstations for tool accessibility and reduced operator movement. Established clear shift-specific process responsibilities, improving collaboration, reducing confusion, and increasing accountability. Enhanced communication across shifts to ensure a unified direction and buy-in from both teams. Results Achieved 10–15 additional scans per shift across four product series—improving throughput and reducing operator wait time. Increased annual revenue from $5.09M to $7.64M, attributed to a 52-week increase in production output. Reduced part mix-ups and backorders, leading to better on-time delivery performance and improved customer satisfaction.