Successes – Praesto Lean Solutions

We're very proud of our track record of success. Some notable implementations and summarized results are described below. If you'd like to learn more about these implementations, or speak to our references at these facilities, please contact us.

Remote Equipment Monitoring Command Center

Long term customer, multiple lean office projects
Notable project in command center, monitoring status of 30K pieces of equipment
- Lean office processes, standard work
- Daily, hourly management disciplines
- Identified and addressed critical element that often caused machines to go unrepaired
- Improved key uptime metric for a net annual benefit of $1M

"I have used Paul at two different companies, in two very different industries, and the results are always stellar. Paul is extremely effective at using his tried and true techniques to understand the challenge at hand, quickly identify the root causes then set in motion a plan to correct them. I would recommend Paul to anyone who is serious about improving their company with lasting results." Ric Davis, Exec Vice President, Cardtronics

Appliance Manufacturer

Long-term customer, multiple projects over 10 year period
Achieved transformational productivity and cash savings that enabled a massive turnaround in company finances
Lean line design – balance, layout, workstation design, operator flexing, supervisor daily disciplines, management training, daily sequencing and load leveling
Finished goods kanban, production planning
Long range, large-scale facility expansion and capital planning

"Praesto Lean Solutions and Paul Boots have been working with us since 2000 when our lean journey started. Paul has brought concepts like flexing labor, Kanban, line balancing, In Process Kanban (IPK), capacity utilization, bottleneck elimination, mixed model scheduling and many others to our operation. Paul not only brings the concepts but he is there through the implementation including the necessary training for sustainment. The majority of labor flexing projects have realized 15% sustainable labor savings and a typical Kanban project reduces inventory by 50% or more. Paul has been vital to our lean journey and operational success and we look forward to working with him again and again". Todd Kaull, Vice President Global Manufacturing, Alliance Laundry Systems

Digital Printing Operations

Complete facility redesign and line layout
Lead-time reduced, productivity & quality improved by 30%
Achieved peak holiday season (800% volume increase in 4 weeks) without need for round-the-clock heroics from line managers

"I had the pleasure of working alongside Paul in a large printing operation, working to take out costs while increasing efficiency and reducing waste in a very complex workflow. The tools he brought to our project reduced our turn times by 30% and cut our rework and labor costs by a similar margin. The project was so successful that elements of it were implemented at numerous other facilities around the world. I wouldn't hesitate to recommend Paul's services to anyone." Corey Christiansen, President, McKay Printing

Photographic & Digital Printing: Paris, France & London, UK:

complete facility lean design and line layout
80% reduction in lead-time
Enabled one facility to offer last-minute Christmas gift option to consumers one day later than competition, generating additional €1M of sales

“Paul Boots has been instrumental in transforming our workflow & process, in a fast-growing on-demand printing business. This was a very well balanced mix of technical skill set as well as communication & training focus - tailor made to our needs”. Renaud Besnard - PhotoBox Group Production Director

Highly Engineered Pump & Compressor Systems

Long term customer, multiple projects in 4 countries over 2 decades
Lean manufacturing:
- Lean line design in low volume, high mix, high variation engineered product manufacturing
- Multiple-card kanban through machining cells
Lean office implementations in engineering and applications processes
- Established design cells for ‘fast’, ‘medium’ and ‘complex’ order types
- Reduced lead-time and improved predictability and reliability

Specialty Steel Manufacturer

Multiple lean line design and training projects
Standout success in Inspection Lab area, reducing lead-time from 14 days to 2 days with a 40% productivity improvement

"I still can't believe how complex we thought it was and how simple you made it", VP Ops

For more information on these projects or to discuss your unique challenges, contact us.

We understand that every business is unique. Dealing with the unique and specific issues of every business we see is made a little easier by being able to draw upon our experiences - knowing what worked and what did not - from hundreds of implementations in the past. Here is a partial list of industries and environments in which we have performed successful implementations: