Portfolio

Challenge
Facing rising labor costs, supply-chain delays, and eroding margins (operating margin had fallen from 14% to 6% in 3 years). Production lead time averaged 28 days and on-time delivery was stuck at 68%.
Desired Outcome
Reduce lead time by at least 40%, improve OTD to >95%, and free up $2.5M+ in working capital tied up in excess inventory.
What Made NovaRising Stand Out

Combined deep shop-floor experience (former plant managers on our team) with data-driven VSM and simulation modeling
Fixed-fee + gain-share pricing model (client only paid 50% upfront, the rest from realized savings – huge trust builder)

Solution Implemented

14-week Lean + Digital Lean transformation
Redesigned plant layout using 3D simulation (FlexSim)
Implemented pull-based kanban + dynamic buffer management
Built real-time OEE dashboards in Power BI connected to existing CNC machines (no new hardware)
Trained 120 employees (yellow-belt level) + 12 internal Lean leaders (green-belt equivalent)

Ongoing Support
Quarterly health checks + remote dashboard monitoring for first 12 months
Results (verified by client CFO)

Lead time reduced 52% (28 → 13.5 days)
On-time delivery rose to 97%
Inventory reduced by $3.4M (freed up cash)
Annual EBIT improvement of $4.1M (11% margin gain)
ROI for client: 8.3× in first year

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