CUSTOM OPERATIONAL SOLUTIONS

From Individual Work Cells to Entire Operations
While each partnership reveals unique operational opportunities, in the broadest sense, manufacturing and distribution processes that are conducive to nGROUP expertise are those involving workers who directly impact productivity and quality while completing manually intensive tasks. nGROUP focuses on areas where products are being made, altered and/or distributed such as the work cells listed below. Alternatively, nGROUP is also utilized to manage entire distribution or manufacturing operations.
  • Assembly
  • Cross-Dock
  • Display Build
  • Fresh Cut Fruit
  • GOH
  • Inspection
  • Kitting
  • Packaging
  • Pick / Pack
  • Prepared Meals
  • Receiving
  • Replenishment
  • Rework
  • Shipping
  • Sorting
  • Ticketing / Tagging
  • Value Added Services

INDUSTRY ISSUES SOLVED

Below are just a few examples of how nGROUP has solved critical business issues such as:
  • Process
    Improvement

  • Driving Down
    Per Unit Cost

  • Reducing Risks and Liabilities Associated with Labor

  • Meeting Quality and Productivity Metrics

  • Creating Greater
    Flexibility

 

Exceeding Cost Per Unit Expectations

Client

Honda Lock America, a Tier 1 automotive supplier, who partnered with nGROUP insourcing production management and engineering support to realize cost, quality and efficiency objectives.

Problem

nGROUP worked with management to benchmark current performance in two plants, assemble a business case for unit cost and then developed a plan to transition production to an area dedicated to unit cost and a floor layout for that area, creating a plant within a plant.

The company’s objectives were to reduce cost and internal headcount, to make space for new equipment, increase productivity and improve inventory management. nGROUP guaranteed cost-per-unit and assumed responsibility for outcomes by managing workflows, setting correct staffing and metric movement. Not only were Honda’s objectives met, they were exceeded.

Solution

“HLA holds itself to the highest possible production and management standards and to better itself in all areas of production, research, management and customer satisfaction. nGROUP is in-house in the company’s Bremen, GA plant where we manage production and provide engineering support for its manually-intensive sub-assemblies.

+30%
30/100
Productivity
+20%
20/100
Employee earnings
-50%
50/100
Overtime

The on-site benefit of immediacy in both improvement decisions and quality inspections and our ability to integrate improvements into other areas of the company has allowed us to effectively guarantee cost-saving and production improvement. We were able to increase productivity by 30% and wages 20% through incentives while reducing labor costs by 35%.”

FRANKLIN SOLORZANO
FRANKLIN SOLORZANO
Executive Vice President of Operations

An Industrial Engineer, Franklin Solorzano joined nGROUP in 2009 and designed the high-impact processes for nGROUP site implementations. For Honda Lock and Key, Solorzano and the nGROUP team created pricing methodology, plant layout and configuration, micro-movements studies, and training and cross-training modules.

 

Reducing Costs And Improving Quality

Client

Sony Electronics engaged nGROUP as part of its corporate mandate to reduce cost throughout the global organization.

Problem

After a successful nGROUP startup in the receiving department, Sony transitioned all processes in its largest North American DC, along with its entire full-time workforce to nGROUP. Resultant savings came in at $3 million dollars, which was a 30+% reduced per-unit labor cost while hitting 100% peak-season shipping quality for the first time in the facility’s history.

Solution

“We were able to assume responsibility for operations including cost, quality, throughput, reporting and labor management for Sony, contributing

+100%
100/100
Shipping quality achieved
-30%
30/100
Labor cost
a large portion of the company’s supply chain group savings. Their service levels improved while maintaining 90% of the workforce and allowing zero lapse in quality or productivity. Our work with Sony was recognized with a nomination for their Global President’s Award.”

Diron Raines
DIRON RAINES
Executive Vice President

Diron Raines leads client partnership engagement for nGROUP. Raines manages assessment and benefits case development to ensure a good fit prior to initiation of projects. He brings years of senior management expertise in strategy practice for a Big Four consulting firm, developing portfolio strategies, manufacturing strategy, operations planning and shareholder value analysis.

 

Delivering Low Risk Staffing Solutions

Client

The client is a global processor of fresh cut produce with multiple plants in North America and 10,000+ employees worldwide.

Problem

They were concerned with liabilities associated with managing a large workforce. Employment of the workforce had been outsourced through a staffing agency but the client wanted to outsource the management of their production as well. Their staffing partner was not capable of delivering the level of management expertise they required.

nGROUP developed a unique labor model specifically for the client’s business that effectively mitigated co-employment risk. nGROUP’s workforce management systems substantially improved productivity, quality and yield. The net effect is a more competitive and profitable business, which has led to nGROUP’s expansion to multiple locations across the nation.

Solution

“The application of our program at this global food processing company produced excellent results against our contractual commitment of: improving efficiency, reducing cost, and maintaining or exceeding current quality levels.


5-50%
50/100
Reduced unit labor cost
19-118%
100/100
Improved pounds p/man hour
5-11%
11/100
Improved yield

“Our results allowed our program to grow into seven facilities across the United States. Our top results in a facility on an annualized basis were: over 300% efficiency improvement, labor spend reduced from 8 million to 4 million in one facility in one year, and yield improvement of 30%. While these achievements are impressive, I personally enjoyed the tremendous growth of the personnel in our programs. We have many examples of personnel that started in General Labor positions and rose to run areas or facilities of their own.

Jim Rossini
JIM ROSSINI
Executive Vice President of Operations

Jim leads the Midwest region to operational excellence. He has focused his efforts in the development of corporate processes to ensure consistent practices throughout nGROUP. Jim partners with executive teams of several national accounts to facilitate performance and strategic execution.

 

Meeting Seasonal Demands While Reducing Costs

Client

One of North America’s largest retailers of value priced apparel and accessories with over 500 stores in North America.

Problem

Their distribution operations are subject to seasonal peaks resulting in low efficiencies and quality issues due to the influx of untrained temporary labor and overtime in excess of 30%. State mandated wage increases resulted in recruiting and retention challenges in a competitive labor market, applying additional pressure in labor costs.

Solution

+9%
9/100
Employee earnings

“The VP of Logistics saw opportunity for improvement in his distribution operations and was looking for a firm to conduct an Engineering Study and to create Work Standards.  When he met with nGROUP we discussed that the results of such information is best realized when the operations team is accountable for achieving and sustaining the cost and productivity benefits, ideally measured on a cost per unit basis.

-21%
21/100
Labor cost
25%
25/100
Output
-90%
90/100
Overtime
Since nGROUP could provide both the Engineering Study with Work Standards and on-going performance management with guaranteed achievement of the cost per unit savings, we were able to achieve their business objectives in the short and long term."

Jim Zimmerman
JIM ZIMMERMAN
Chief Operating Officer and Co-Founder

Jim is a leading expert in Operations Process Outsourcing in the areas of manufacturing and distribution. As COO, Jim's has responsibility for operations management and the development, design, operation, and improvement of the systems that create and deliver nGROUP's services. Jim’s vast experience partnering with industry leaders throughout the U.S. has provided insight into best practices, and enabled him to design outcomes that combine proven techniques for both clients and his team. Jim is a graduate of Virginia Tech with degrees in Industrial and Systems Engineering, and Statistics.

 

Turning the Impossible into Possible

Client

Optoro partnered with nGROUP in order to rapidly startup a new facility in a highly competitive labor market, all while trying to reduce labor cost in unit cost departments.Further, the Optoro management team sought to be relieved from ancillary issues to better focus on their core tech business.

Solution

+12%
12/100
labor cost reduction
in unit cost departments

12%+ labor cost reduction in unit cost departments . Successful implementation of employee engagement strategy that made Optoro an employer of choice; thereby retaining and recruiting a skilled labor force. On time achievement of new facility start-up, all while meeting and exceeding production goals.


“A collaborative, vested partnership with strong communication and trust between nGROUP and Optoro achieves excellent results. nGROUP works seamlessly in Optoro’s facility. This relationship enables Optoro to achieve immediate goals and support long term business strategy.”

David Hair
DAVID HAIR
President and Co-Founder nGROUP

David's primary focus at nGROUP is leading change within nGROUP to meet the company’s and his clients’ future needs. He is committed to driving growth through excellence and integrity, and believes in treating clients, vendors and associates with respect and dignity. David has a BS in Business Management from Indiana University. He served as an officer and a pilot in the U.S. Navy upon receiving his degree.

 

Achieving Corporate Objectives through 
Tactical Redesign

Client

Pacific Logistics ( 3PL ) partnered with nGROUP to achieve a complete overhaul of a multi-client warehouse operation with the goal of reducing labor cost.

Solution

+15%
15/100
Reduced labor cost

Reduced labor cost by 15% to achieve 35% labor to revenue goal Transitioned warehouse operations to new warehouse management system (WMS). Implemented new floor layout to better utilize space and improve productivity. Developed tracking and reporting to provide insight into profitability by client in multi-client operation.

nGROUP values old-fashioned commitment… ‘Tell us what you will do, and do what you say.’ After an extensive engineering study, we explained to Pacific Logistics what results they could expect. Our promises are backed by a financial contract. We deliver what we promise. Guaranteed.”

Jim Zimmerman
JIM ZIMMERMAN
Chief Operating Officer and Co-Founder

Jim is a leading expert in Operations Process Outsourcing in the areas of manufacturing and distribution. As COO, Jim's has responsibility for operations management and the development, design, operation, and improvement of the systems that create and deliver nGROUP's services. Jim’s vast experience partnering with industry leaders throughout the U.S. has provided insight into best practices, and enabled him to design outcomes that combine proven techniques for both clients and his team. Jim is a graduate of Virginia Tech with degrees in Industrial and Systems Engineering, and Statistics.