Case Study: ThermoFab achieves 50% shorter lead times and near 90% on-time delivery with WM Synergy

Plastic Thermoforming Company Finds Success with Theory of Constraints and ERP VISUAL

ThermoFab, a 35‑employee plastic thermoforming company, was losing ground to low‑cost competition and struggling with long lead times and late deliveries that hurt profitability. To tackle these challenges they worked with WM Synergy and adopted the Theory of Constraints (TOC) approach alongside Infor ERP VISUAL and its DBR (Drum‑Buffer‑Rope) scheduling capability to improve throughput and service.

WM Synergy led a Fast Track VISUAL DBR implementation and TOC/DBR training, going live in 39 days; the result was a roughly 50% reduction in lead times (from 6–8 weeks to 2–3 weeks), on‑time performance near 97.5%, a 10% revenue gain in the first three months and sales growth of about 100%, substantially improving ThermoFab’s competitiveness and customer service.

ThermoFab

Tom King

President