MAMMOTH RESULTS
Operations Consultant
Recent Work
Hot tub pump and filter manufacturer
A US-based hot tub pump and filter manufacturer faced significant operational challenges at their Tijuana, Mexico plant. Inventory had surged to $20.3M, the plant was disorganized, processes were undocumented, and the warehouse was poorly managed. On-time delivery had plummeted to 54%. The company urgently needed to reduce inventory to $10M and improve on-time delivery to 90%.
Mammoth Results was brought in to address these issues. We conducted a thorough assessment, formed a cross-functional team, and revamped the forecasting, planning, and inventory management systems. Production workflows were streamlined, performance tracking tools were implemented, and the team was trained in LEAN methodologies and problem-solving techniques. Major improvements were made in warehouse management, safety protocols, and Standard Operating Procedures (SOPs) were established to ensure long-term stability.
Within 12 months, inventory was reduced to $9.8M, and on-time delivery increased to 95%. Standard KPIs were introduced and reviewed in weekly meetings, with standardized communication of results. Beyond meeting immediate goals, the company is now set up for sustained operational success with improved processes and a more engaged workforce.
Food Manufacturer
A U.S.-based food manufacturer came to Mammoth Results facing serious operational challenges. They were dealing with stagnant revenue, long lead times of 7-12 weeks, and inconsistent production that led to only 77% on-time delivery. Inventory inaccuracies were mounting, and customer satisfaction was in decline.
We stepped in and led a cross-functional team to address these issues head-on. Using industry best practices, experience, and LEAN methodologies, we streamlined their processes and eliminated identified waste. We also implemented real-time inventory management and warehouse organization to correct inaccuracies and optimize the flow of materials. We trained their team in problem-solving techniques and established a robust KPI tracking system to monitor ongoing performance.
Within six months, the results were clear: on-time delivery soared to 92%, lead times were slashed to 1-4 weeks, and inefficiencies were cut by 50%. The company saw a 50% boost in year-over-year sales, and the new processes continued to drive operational success long after our work was done.
U.S.-based glass and tile manufacturer:
A U.S.-based glass and tile manufacturer approached Mammoth Results after struggling with cash constraints, poor on-time delivery (41%), high employee turnover, and inefficient use of space at their Mexico operations following two difficult acquisitions. Our mission was to stabilize the company, improve cash flow, and streamline both U.S. and Mexico sites.
We started by optimizing resource allocation, improving supply chain and order processing, and rationalizing warehouse and production space. The Mexico manufacturing and warehouse footprint was reduced from 150,000 sq/ft to 90,000 sq/ft without affecting output. Employee engagement efforts significantly lowered administrative turnover from 31.8% to 4.5%. We also implemented a cost-reduction initiative that identified and eliminated inefficiencies across the organization.
Within two years, on-time delivery surged to 91%, and the company achieved $2.7M in cost savings. These improvements positioned the business for future growth, reduced inventory from $9.2M to $4.8M, and helped launch new products that now account for 35% of sales. Mammoth Results helped turn a struggling business into a streamlined operation ready for long-term success.
Irrigation manufacturer
A U.S.-based irrigation manufacturer faced operational challenges at its Maquiladora plant in Tijuana, Mexico, which employed over 1,000 staff and the manufacturing plant had 90,000 sq/ft. The facility specialized in injection molding, assembly, brass machining, and tool repair, yet struggled with high defect rates, on-time delivery, high inventory and customer service issues.
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To transform operations, the company implemented comprehensive improvements in quality systems through LEAN methodologies, Fast Response techniques, and PFMEA analysis, resulting in an impressive 82% reduction in Defective Parts Per Million (DPPMs). Delivery performance soared to 99%, and inventory levels decreased by 14%, significantly enhancing overall efficiency. Additionally, the restructuring of overhead costs returned millions in net profit.
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Safety also became a priority, with the plant achieving 387 accident-free days through a cultural shift and new safety programs. The commitment to continuous improvement was demonstrated through 12 Kaizen events annually, earning nine team awards in just three years. With a robust tooling strategy and world-class capabilities in mold maintenance and repair, the company is now positioned for sustained operational excellence and growth.
Toy manufacturer
A $3B toy manufacturing company, with a $200M division, was facing rising labor costs, employee shortages, and operational inefficiencies at their Ohio-based plant. Looking for a solution, the company turned to Mexico for its manufacturing needs and engaged Mammoth Results to lead the entire project. With a $13M budget, including $9M allocated for new equipment, we took responsibility for selecting a 190,000 sq. ft. manufacturing and warehouse facility. We handled the location selection, negotiated a lease and an agreement with a Shelter company, and led the recruitment and training of 500 employees from the ground up.
The project included the installation of new equipment, as well as the transfer and installation of equipment from the Ohio plant to the new Mexico facility. As a result of our expertise in LEAN methodologies and continuous improvement, we optimized the plant's operations from the start. Production began just 6 months after signing the lease and Shelter agreement, and within 9 months, scrap rates and product quality surpassed those of the 30-year-old Ohio factory. The entire project was completed 5% under budget, and the new facility provided the division with a streamlined, efficient operation and a long-term competitive advantage.
Test Automation Engineering Firm
A test automation Engineering company, sought to standardize its operating procedures and improve efficiency as it transitioned from its core business to a SaaS model. To facilitate this, they engaged Mammoth Results.
We developed 16 Standard Operating Procedures (SOPs) for critical processes, effectively addressing repetitive business challenges and reducing the cash conversion cycle from 90 days to 45 days. We introduced a formal project management process to enhance deadline adherence and revamped their weekly customer communication for improved transparency. To maintain accountability, we implemented a KPI structure with weekly reporting. Additionally, we restructured the hiring process by establishing a justification protocol for new positions, conducting capacity planning, and standardizing job descriptions and benefits packages.
We established a software engineering organization in Mexico, where resources were approximately 60% the cost compared to the U.S. and were easier and faster to find and employ.
These changes equipped Good Automation to effectively manage its growing workforce, meet client demands, enhance project completion times, and lower overall costs.