Client results

What changed for clients.

These are documented cases from client work in operations, supply chain and procurement, each labelled with its status: realised result, implemented milestone, plan or design, or assessment. Figures that come from a model are marked as modelled.

Showing all 18 cases

  1. 01Global manufacturing turnaround
  2. 02About 40% fewer backorders and up to 39% more output at critical steps
  3. 03The digital twin that deferred expansion and saved $1M
  4. 04Business continuity planning for neurovascular devices
  5. 05US warehouse optimisation
  6. 06A first cell-therapy BLA, filed on the planned date
  7. 07Nitinol sourcing: partner selected at about half the incumbent's manufacturing cost
  8. 08A $20M savings plan from redesigning a global manufacturing network
  9. 09Chain of identity and custody, designed and implemented end to end
  10. 10Logistics operating model and 3PL selection for a medical-device manufacturer
  11. 11Operational due diligence for a cosmetics acquisition
  12. 12Cleanroom kitting that saved two hours per batch in its pilot
  13. 13Manufacturing scale-up for single-use endoscopy
  14. 14Quality and lab staffing set on the hours behind the tests
  15. 15Cleanroom material flow and replenishment design
  16. 16Global post-merger integration
  17. 17Raw-material buffers sized to usable stock
  18. 18Operational readiness for fivefold growth at a medical-device manufacturer

Industrial manufacturing · Global

Global manufacturing turnaround

Realised result

₪15M (~$5M) first-year savings · EBITDA up 10% · 12 months

Both numbers were measurable in the P&L within those 12 months.

Situation and work

The situation

Another firm had already done the analysis. There was still no turnaround plan, and nobody had yet worked out the operational decisions that would turn the analysis into numbers.

The work

Opyflow wrote the turnaround plan and carried it out: it led the operational restructuring, realigned the leadership team and ran the procurement optimisation.

Summary only · full case on request →

Distribution & logistics · United States

US warehouse optimisation

Realised result

99% inventory accuracy (physical count), maintained after handover · 75% fewer picking errors

The client's own team runs the floor today.

Situation and work

The situation

Nobody trusted the warehouse's numbers. Inventory records had drifted away from what was on the shelves, and picking errors compounded downstream.

The work

Opyflow rebuilt the warehouse together with the floor team. Along with a redesigned layout and new operating procedures, the rebuild brought in Kanban controls and upgraded digital tools.

Summary only · full case on request →

Realised result

About ₪6M (~$2M) lower contracted logistics cost over the five-year contract, around 20% · Contract signed, model running · Three providers evaluated, two finalists · One partner running logistics for the plant

The partner, based in the plant's region, holds inventory and supplies the plant on a fixed rhythm. Kitting, packing and returns have moved off the production floor to the partner.

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Assessment

Supply chain assessed end to end · Critical partner dependencies identified · Recommendation to proceed delivered

The assessment identified internal knowledge gaps and a critical external dependency. Opyflow recommended proceeding, and the acquirer proceeded.

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Realised result

Two hours saved per batch, on the first production day · 45% of observed operator time spent waiting (baseline) · Hundreds of individual items consolidated into a small set of kits

Materials reach operators in the order the process uses them, which cuts the time they spend waiting.

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Realised result

Pilot line built to the design, 15,000 units a year · Volume production routed to a contract manufacturer · Scenarios to 1.5 million units kept as expansion options

The make-or-buy criteria pointed to the contract-manufacturer route. Each larger step is released only when real volume justifies it.

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Plan or design

16 staff-hours per batch for QA documentation alone (modelled, lower estimate) · Lab staffing and shift coverage set on the modelled hours · External tests reviewed for bringing in-house

A change in volume or in how long a task takes appears in the resource plan first, ahead of any effect on the floor.

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Plan or design

Design approved by all stakeholders · Kanban and min/max replenishment specified · Dedicated logistics role defined

The design gives material movement its own owner, who runs it as a service to production. The plant is under construction.

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Life sciences · Europe and Israel

Global post-merger integration

Realised result

Day-1 on time · No operational delays · The quarter's sales delivered

From the first day, the combined business read as one company.

Situation and work

The situation

Two operating cultures had to come together under one deal. When Opyflow was called in, the European parent and its Israeli team did not trust each other and worked in very different styles. How Day-1 went would set the tone for the rest of the integration.

The work

Opyflow set up the PMI office and ran it for both sides. It split the integration into small workstreams with few people and their own milestones, starting with small steps. It moved the critical decisions to the front and gave both sides the same picture of progress. The integration then ran on the office's workflows, governance and execution routines, and Day-1 landed five months after Opyflow was called in.

Summary only · full case on request →

90% of clients return for additional work. A client is named only with its approval, and the case goes up under the client's name the day that approval arrives.

We are done when it's in the P&L.

Describe the situation to the senior person who would do the work. You don't need to prepare data for it, and if we are not the right firm, we will say so.