Palliser Furniture Ltd. – North American Operations
Canada: Winnipeg, MB; Airdrie, AB
USA: Troutman, NC
Mexico: Las Colinas; Saltillo
Industry: Manufacturing
Service Line: Operational Review, Restructuring & Project Execution
Project Description: Corporate Restructuring, New Product Development Consistency & Speed-to-Market Improvement
Corporate Restructuring
Provided project management and floor plans for the corporate restructuring of the Winnipeg Upholstery Group. This included 420,000 sq. ft. and over 1,200 team members in 8 months. Focused layout upon lean, standardized workstations and cross-training to become more agile. Reviewed management goals and ensured stakeholder understanding and alignment. Prepared options for detailed layouts, and sold one to the executive. Coordinated the moves, external contractors, and internal groups as well as working with our insurer and underwriters to mitigate consequential damage concerns. The planned loss of 4 workdays was reduced to just 3 days. A monthly lease payment was saved going forward, along with one 104,000 sq. ft. plant no longer required and deemed surplus.
New Product Development Consistency & Speed-to-Market Improvement
Met with sales and marketing team to evaluate sofa seating concerns which also unearthed market agility concerns with major US retailers. Undertook a vigorous review of sofa new product design processes. Provided a series of recommendations in a preliminary report. Sold the concept of “platform design” to eliminate multiple concerns simultaneously. This new frame design approach simplified and standardized frame assembly techniques leading to better quality, less rework and boosted throughput at all North American factories. With a consistent frame and springing method came seating standards in which marketing could now rely. These consistent design elements allowed foam, fabric and leather patterning work to be significantly reduced with 90% of those parts now standardized. New assembly hires became productive faster. The best observed time previously from sketch-to- reality was 15 business days. This new approach to design routinely met a 4-business day turnaround for a new style, while reducing overall frame costs by over 30% for annual savings of over $900K annually.
