Explore how Poka-Yoke Solutions has transformed businesses with tailored operational processes.
Studies
Case
Our results are so good, they are almost unbelievable*
*read these stats and you'll agree
INCENTIVIZED training completion
94%
3 year Growth
50%
SOPs Documented
350+
Roles Defined
43
After Implementing the Poka-Yoke Process™:
Primary Challenges:
100% paper process (order processing, scheduling and billing)
Manual data entry
Unclear organizational structure
Operations leader performing tactical functions
Breakdown in communications between departments
Employees
175
Family owned Company
Annual Revenue
$50M
Company Snapshot
Industry: Trucking & Transportation
Streamlined and Digitized Processes: Created new order-to-cash workflows and implemented them electronically, replacing all previous paper processes.
Built a comprehensive organizational structure and chart, giving the blueprint on who to hire for management and staff allowing the Operations Leader to move into the COO position.
Achieved Employee Training and Connection: Built out a centralized online training system and rolled it out to 175 employees, achieving a 94% incentivized training completion rate.
Recent 25% turnover in management resulting in loss of foundational company process knowledge
$2M in inventory unlabeled and unorganized
Long ship times and crowding of the warehouse
Employees
30
Family owned Company
Annual Revenue
$30M
Company Snapshot
Industry: Warehouse & Distribution
Inventory Reconciliation: Created and led a robust inventory reconciliation plan, improving inventory accuracy and ongoing inventory management.
Transitioned to Electronic Orders: Moved from paper-based to electronic order processing, streamlining operations and reducing errors.
Streamlined Warehouse Processes: Implemented a 3-phased receiving and fulfillment process, allowing for Warehouse Management System to ultimately fill orders quicker and more accurately.
Comprehensive Training Programs: Documented processes company-wide and rolled out extensive training programs to ensure consistency and knowledge retention.
Implemented NetSuite ERP System: Added order visibility across the organization and operational efficiency and integration across departments.
Improved Communication Systems: Established a communication system that synchronized the Fulfillment team with Customer Service, improving coordination and response times.
New Product Launch Process Flow: Created a structured process for product launches, streamlining the introduction of new products.
Enhanced Customer Service: Reverse engineered hundreds of pages of documentation and product information into a step-by-step ticket troubleshooting flow, improving time to answer tickets and onboard new agents.
100% paper process (scheduling, orders, shipping and billing
Employees
200
Operates in 75+ Countries
Annual Revenue
$150M
Company Snapshot
Industry: Technology
Implemented Electronic Orders and Billing: Created and put into action a 4-Phased plan to transition all teams from paper to electronic processing, ensuring team buy-in and allowing for quick scalability.
Improved Order Accuracy: Designed a product selector tool supporting 26,000 combinations of order items, ensuring only compatible combinations could be selected.
Global Expansion: Efficient processes and ERP implementation allowed operations team to manage a 3500% increase in order volume while only adding 2 people.
Process Automation: Automated several key operational processes, including with vendors, to reduce manual work and improve order accuracy.