Driving Rapid Value Creation in Manufacturing
These Case Studies and Stories of Success demonstrate the power of my strategic leadership, my ability to assemble the right team and drive rapid, significant improvements in manufacturing.
Equipment Mfg. Case Study #1: Service Efficiency and Production Visibility Optimization
1
Challenge
Improve first-time fix rates and equipment uptime for a fleet of 60,000 customized trucks. Enhance production KPI visibility and reporting efficiency.
2
Solution
Implemented AI-driven part recommendations and real-time KPI dashboards.
3
Key Achievements
- Automated parts recommendation for service jobs
- Deployed near real-time production KPI dashboards
- Eliminated manual reporting processes
4
Business Impact
- 25% increase in first-time fixes
- 28% faster completion of service jobs
- 35% reduction in service job costs
- 25% increase in revenue per transaction
- 70% reduction in time to determine related parts (from 20 to 6 minutes)
- Saved 95 minutes daily in KPI reporting and shop floor walks
5
Time to Value
- Service improvements: Under 60 days
- Production KPI enhancements: Less than 30 days
6
By leveraging data, AI, and streamlined processes, we achieved substantial gains in efficiency, cost reduction, and revenue growth—all within remarkably short timeframes.
Stories of Success
A Tier 1 Automotive Supplier
Read more about the strategic overhaul of this automotive design group
I led the strategic overhaul of this automotive design group's prototyping and design processes, focusing on streamlining their global engineering operations. With expertise in designing and manufacturing chassis, suspension, and braking systems, the company was facing mounting challenges in managing the complexity of designs originating from multiple engineering hubs, including Detroit and other major automotive centers.The need for a more cohesive and efficient design process was evident, especially as the company continued to push innovation in active suspension and damping systems.
I orchestrated and nurtured the vision of making improvements to the engineering process. Myself and my team of automotive pr0duct management leaders worked with the execs to provide a process visions. Then we had to determine the best path in terms of a technology that would enable the vision to come to life. We selected an industry leading Product Lifecycle Management (PLM) system that brought structure and efficiency to their product development processes. This system was designed to improve collaboration among their globally distributed engineering teams, simplify design revisions, and significantly accelerate the product development cycle. By establishing new processes through this PLM solution, the leadership team gained much greater control and visibility over the entire design lifecycle.
These enhancements resulted in increased prototyping engagements and a substantial rise in the number of design projects completed each quarter. The leadership was empowered to make more informed decisions, reducing time-to-market and driving greater innovation across the company’s product portfolio. The streamlined design process ultimately strengthened the company’s position in the competitive automotive space, particularly in the high-performance vehicle segment.
A Hotel Bedding Manufacturer
Learn more about my approach of enabeling a data-first strategy.
I, Daren Fields, led the transformation of this high-quality bedding manufacturer by providing strategic vision and hands-on leadership throughout the project. With their reputation for craftsmanship and industry experience, the company was struggling to maintain operational efficiency amid rising material costs and supply chain disruptions.
Upon engaging with the leadership team, I guided the development of a comprehensive strategy to address critical pain points. These included unreliable inventory planning at their Mexico plant, which was leading to production inefficiencies, partial shipments, and delayed customer deliveries. Additionally, their sales forecasting and field estimating processes were underperforming, which compounded their inability to meet growing customer demand.
Under my leadership, we successfully implemented a SaaS ERP platform that streamlined operations across all departments, from manufacturing to distribution. My team also deployed a cutting-edge SaaS quoting and configuration system to improve the customer experience, enabling faster, more accurate orders. To complement these systems, we developed custom field applications tailored to the company’s unique business model.
A key element of my approach was instilling a data-first strategy. We implemented tools that captured and analyzed key performance data, which informed better decision-making and resource allocation. This comprehensive, data-driven transformation not only reduced operational inefficiencies but also enhanced the company's ability to forecast demand, manage inventory, and improve profitability. Ultimately, these initiatives positioned the company to continue growing and thriving in an increasingly competitive market.
High Tech Mfg. Case Study: AI-Driven Sales Efficiency Enhancement
1
Challenge
Optimize sales procedures and uncover customer behavior insights for a manufacturing client.
2
Solution
Started teaching the employees and managers to start using basic AI prompting techniques using public LLM's
3
Challenge
Enabled employees wanted to start leveraging the power of AI on their own customer data
4
Solution
Implemented comprehensive data strategy, enterprise data platform, and AI-driven analytics.
5
Key Achievements
- Deployed advanced customer profiling and segmentation
- Implemented AI-powered personalized product recommendations
- Developed predictive churn model for proactive retention
- Optimized marketing campaigns through RFM (Recency, Frequency, Monetary) analysis
6
Business Impact
- Significant improvement in sales process efficiency
- Enhanced customer lifetime value (CLV)
- Increased conversion rates through targeted marketing
- Reduced customer churn through predictive analytics
7
Time to Value
Under 60 days (Once data infrastructure was in place)
Past Clients & Project History
- BWI Group (Former AC Delco)
- Industry: Automotive
- Year: 2018
- Project: PLM Enhancement and Technical Product Enhancements
- Biamp
- Industry: Electronics
- Year: 2023
- Project: Digitial Eveloution, ERP Replacement, AI enablement, dealer sales, warehouse and manufacturing improvements
- PGT Windows
- Industry: Commercial Windows
- Year: 2021
- Project: Pricing, Quoting and Ordering improvements.
- Watlow
- Industry: Manufacturing (Heater Elements)
- Year: 2016
- Project: Full Digitial Transformation across the enterprise
- Norland
- Industry: Civil Engineering
- Year: 2021
- Project: Digitial Transformation across 12 divisions
- Interpac International
- Industry: Packaging (Bottles and Containers)
- Year: 2019
- Project: ERP Transformation Implementation - Global
- TAS Energy
- Industry: Data Centers (Modular)
- Year: 2019
- Project: ERP Implementation and Shop Floor enhancements
- Galleher
- Industry: Flooring
- Year: 2018
- Project: Digital Transformation
- Swanson Group
- Industry: Specialty Wood
- Year: 2019
- Project: ERP Implementation
- Fabtex
- Industry: Bedding
- Year: 2017
- Project: Digitial Transformation, ERP Implementation
There are more engagements and projects, but this sampling should give you an idea of my experiences.
Additional Notable Projects
- Darn Tough
- Industry: Apparel (Socks and Clothing)
- Year 2018
- Lime Scooters
- Industry: Transportation/Mobility
- Year 2018
- NVent
- Industry: Electrical Supplies
- Year 2017
Career Summary
- Total Project Exposure: 380+ systems, projects, and engagements
- Executive interactions: Over 250 executives and leaders
- Experience Types: Wins, Losses, and Ties
- Timeline: 2012-2023
- Industries: Manufacturing, Government, Automotive, Electronics, Medical, Wood Products, Non-Profit, Law Enforcement, and more
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