Case Study: a leading plastics manufacturer achieves 4x EBITDA growth with Elliott Davis operational transformation

Leading Plastics Manufacturer boosts on-time delivery to 93% with Elliott Davis

A leading plastics manufacturer, recently acquired by a private equity group, was struggling with poor on-time delivery, low equipment effectiveness, and a high cost structure. They engaged Elliott Davis to help define and accelerate an operational transformation for their U.S. operations to boost performance.

Elliott Davis implemented a solution leveraging DMAIC principles across five work streams, including data optimization, OEE root-cause analysis, and Lean implementation. This approach dramatically increased EBITDA by approximately four times, reduced order backlog by 75%, and improved on-time delivery from 45% to 93%. The vendor also helped the customer achieve $480K in annualized savings from scrap reduction and a 41% increase in overall equipment effectiveness.