Notable Project Achievements
We work with companies of all sizes, including several of the Fortune 50 as well as many mid- and small-cap companies. Our projects include questions of strategy, tactics and operations. Regardless of the size or scope of the question, Caplan has an established record of delivering significant cost avoidance, productivity improvements and other savings.
10-year Site Master Plan
This $50+ million project included the strategic planning for a single-category new site in Egypt. Caplan’s involvement included project team facilitation, candidate property analysis, site selection, facilities planning and logistics support.
5-year Site Master Plan
This $50+ million project involved integrating a new business into an existing plant in Korea. Caplan was responsible for determining the location of the new production lines as well as incorporating new materials and support processes into the existing plant layout.
5-year Site Master Plan
This $50+ million project involved transitioning a business unit to a new production platform at an existing plant in France. Scope included: developing a phasing plan to site-clear the existing production lines and install the new production lines; expanding a second site business; conducting a logistics analysis to determine the effect of increased throughput on the site’s integrated supplier and automation infrastructure (AGV’s, pallet conveyors and ASRS); and, a broad site support facilities upgrade project. Our solution integrated scope and cost in a 5-year phasing strategy.
5-year Site Master Plan
This $10+ million project involved a change in sourcing strategy that resulted in a 50% increase in this site’s production volume and a 75% increase in production SKU’s covering 4 of the site’s businesses. In addition to developing scope and cost for the property, plant and equipment changes, Caplan also supported the warehousing and material handling design aspects of the project.
4-year World-Class Sustainability Program with a 20-year Net Present Savings of US$30 million
Our client asked us to identify utilities system losses and develop a world-class sustainability program for a 5-year old manufacturing plant in Brazil. The study identified more than 40 cost-savings projects to reduce annual electric, natural gas, water and waste water costs by US$3 million per year.
