Implementation Services

Stonewood Homes

ViAGO Client. TOC3 practitioner: Andrew Kay (Project Manager) & Andrew Cranwell. Credit to Phil Spitalney TOC Contractor.

Product: Custom Built Homes

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Issues

Long lead time to build homes
Unhappy customers
Unhappy sub contractors
High Stress levels
Poor profitability

Action taken, changes made

On-site consulting project: Critical Chain Project Management
Installed Critical Chain based scheduling and Pipeline Management
Supervisors and Subcontractors trained to follow the new system

Measure	Before	3 months after CC project installed	Improvement
Lead Time to build standard 3 Br modern home	110 – 120 days Industry standard	73 Days consistent plus or minus 5 days	30% - 35% lead time reduced
Cash Flow	Not bad, sometimes going to 30-60 days.	Great	Suppliers/contractors paid on time, and before time if they are in a tight spot.
Progress Payments	Unreliable	Reliable on time	More projects hitting payment stages more regularly = predictable cash flow
Profitability	Struggling to break even	Tangible difference.	As a volume business the ability to produce more = Better returns.
Customer Satisfaction	Lots of complaints	Lots of praise	One home on the market 2 weeks early (63 day build).
Contractor Satisfaction	Lots of complaints	Lots of praise for everyone	New levels of trust and payments on time
Stress levels	High – many sleepless nights	Much lower, ability to switch off and leave it to others.	Taken holidays for first time in years

New Zealand Press:

Tauranga Gets Gold!

“Stonewood Homes, Matamata New Zealand enjoyed phenomenal success with two gold medals in the House of the Year Awards 2008. They won the prestigious Category Winner and Gold Medal for their entry in the Homes $350,000 to $450,000 category.

“Some of the standout results (they are all standout, these are the real biggies) …

I can sleep at night with the knowledge that the projects are where they should be and there is a workable plan for the completion of the home.

Clients have a completion date that is real.

I have been away on holiday twice since the implementation of our project board, this has been without the need to take a phone for fear of the need for my direction. More importantly upon my return everything is still in order.

We have clients that are in their completed homes that consider us their friends after the process of building their home. They tell us their personal news and take delight in us sharing parts of our lives with them. This is a real breakthrough.”

Kevin Norris, Owner Stonewood Homes, Matamata, New Zealand

Electrolux Refrigeration Plant Theory of Constraints Case Study OLD

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Exepron

Exepron is a unique multi-project Critical Chain Project Management Software solution with embedded real time intelligence to plan, schedule and execute projects.

Exepron answers the 7 most critical questions of project management in real time.

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News Release

NEWS

Stonewood Home Success Story

Stonewood HomesViAGO Client. TOC3 practitioner: Andrew Kay (Project Manager) & Andrew Cranwell. Credit to Phil Spitalney TOC Contractor.Product: Custo...

Electrolux Refrigeration Plant Theory of Constraints Case Study OLD

The following client has achieved substantial results with TOC after Lean and some Six Sigma practices where already embedded in the organisation. So ...

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“We have lowest ever late orders in our entire history. From 70% late 6 months ago to just 2 orders late last week.\" “We now have the platform to take off like a fighter from an aircra...

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The Problem with ProjectsThe problem with projects is that all projects have problems. Some are more severe than others. When 4 out of 5 projects are reported to fail; either not delivered o...

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Step 1: The best way to start is to do some reading and some background research.Almost everyone who goes onto transforming their business with TOC has read \'The Goal\' by Dr Eliyahu Goldratt...

Testimonials

Bambach Wires and Cables

“We have lowest ever late orders in our entire history. From 70% late 6 months ago to just 2 orders late last week." “We now have the platform to take off like a fighter from an aircraft carrier and not lumbering off down an interminable runway like the Spruce Goose”, Bill Gale, Director Bambach Wires and Cables, Sydney

Electrolux Testimonial

"Over the period of 2008 thru 2009, during supposedly the worst economic conditions since the Great Depression, we have used TOC to unlock the hidden capacity in our business and sell it into the market place. The result of this has been to shift our Operating margin from 5.1% to 13.1%, our profit increased by $19.88m, and our volume went up by 6.5...

Paul Winterflood

We have had some dramatic changes to the business in recent years including new ownership. However, we are still running the same system you helped install - it just works!" Paul Winterflood, Manager Production Operations, Mackies Group of Companies

Gigangit

We got enough space now to play cricket”, "Rework has virtually been eliminated" Gigangit, Production Manager, Best Bar Reinforcements, Melbourne

Terry

“We have to wait a while before we can say we are making more throughput but I can say we are making the same as before but so much more easily”. Terry, Finance Director, Best Bar Reinforcements Perth

Dragi

“We were averaging 74 tonnes per day now that has jumped to 87 tonnes per day after only 8 days”. (+18%) Dragi; Production Manager, Best Bar Reinforcements, Melbourne

Rick

“I can load four trucks now in the same time as one before” Rick: ecstatic Day Shift Truck Loader

Jessie

"My team no longer need to come to me to know wh at to do, the boards show them”. “Loading trucks and meeting delivery is now just so easy” Jessie: Afternoon Shift Foreman, Best Bar Melbourne

Brad Johnston

“I’m very pleased with that” commenting on the consistent and increased flow of product trough the plant (known for his understatements) Brad Johnston: Operations Director, Best Bar Reinforcements, Perth

Grant Johnston

"That’s truly amazing” Commenting on >75% reduction of WIP in less than 3 weeks and total elimination of back orders. Grant Johnston: Managing Director, Best Bar Reinforcements, Melbourne

Bruce Drummond

“We are more confident in ourselves when responding to the market. Now we can quote dates and know we can deliver.” Bruce Drummond, Owner and MD, Millbrook Furniture, New Zealand

Aiden Kavanagh

“I have to spend less and less time on the factory floor trouble shooting and getting production to flow” “We have lots more capacity now that we are better organised and can schedule properly.” “We have a true pull system: The schedule comes from the customer. We do whatever they ask and resource accordingly”. Aiden Kavanagh, Owner Kavanag...

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