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.
  • Captured Policy Signatures: Implemented electronic signature captures providing for easier audits.
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Company was Acquired!
SOLD
Annual Savings
$347k
Weekly Man Hours Recovered
107
Faster ORDER TO SHIP SPEED
86%

After Implementing the Poka-Yoke Process™:

Primary Challenges: 

  • 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.
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Company was Acquired!
SOLD
Employee Participation
100%
Annual Savings
$803k
Weekly Man hours Recovered
240

After Working with Poka-Yoke Solutions:

Primary Challenges: 

  • Low company morale and unclear responsibilities
  • Poor communication between locations
  • Recent loss of key account (12% of revenue)
  • Change in primary management
 Employees
48
Inc5000
fastest growing company
Annual Revenue
$40M

Company Snapshot

Industry: Marketing/ CPG Product Sampling

  • Organizational Restructuring: Successfully re-structured the organizational chart to improve management and operational clarity.
  • Scalable Solutions: Implemented scalable processes which balanced workload to support future growth and expansion.
  • Employee Morale and Engagement: Boosted employee morale and engagement through structured processes and clear communication channels.
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Roles & Responsibilities
Clear
Efficient employee training system
NEW
Year over Year Growth
15%
Improved order to ship speed
78%

AFTER WORKING WITH POKA-YOKE SOLUTIONS:

Primary Challenges: 

  • Lack of leadership; no management or structure
  • Poor communication and cadence 
  • Inefficient product launch process
  • High employee turnover
 Employees
55
High growth start-up
Annual Revenue
$80M

Company Snapshot

Industry: Beauty / E-Commerce / Warehousing & Fulfillment

  • 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.
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improved forecast accuracy
79%
Increase in Service up-time
94%
Decrease in days sales outstanding(DSO)
95%
Quicker Ship Time
83%

AFTER WORKING WITH POKA-YOKE SOLUTIONS:

Primary Challenges: 

  • Lengthy outstanding payments
  • Inaccuracies in orders, shipments and billings
  • Poor time management among employees
  • 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.
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