Success Stories, Real Results with TTT Consulting

Success Stories

From Frustration to Flow:

Real Results with TTT Consulting

Case Studies

Discover how our solutions have driven success for our clients. Explore real-world examples showcasing innovative strategies, measurable results, and impactful outcomes across various industries.

OIL AND GAS COMPANY

Leading Manufacturer of High-Performance Steel Tubes for Critical Applications)

Problem

Low engagement, high turnover, and no accountability culture
Entirely reactive maintenance, daily firefighting
6 recordable safety incidents/year, unsafe and unstable workplace
OEE below 40%, major downtime and inconsistent output
Low process capability, unable to meet critical quality specs
Risk of losing production license due to audit nonconformance
Under customer surveillance for repeated quality failures
8 quality claims/year, costing $3M+
Delivery times of 3 months, severely affecting trust and growth
Annual financial loss of $300K and $13M in unrealized EBITDA from $90M revenue

Approach:

Daily Management System (DMS): Deployed tiered huddle structure (T1 frontline, T2 supervisors, T3 management) to visualize performance, align priorities, and drive escalation discipline.
Waste and Hazard Awareness: Trained all team members in Lean Thinking to see waste and identify safety hazardsdaily embedding “eyes for waste” as a habit.
Visual Escalation Process: Designed and implemented a tiered escalation system with visual triggers and clear ownership ensuring swift, structured response to abnormalities.

Gemba & Kata Coaching: Conducted routine Gemba Walks and practiced Coaching Kata with leaders and frontline developing problem-solving capabilities where the work happens.g a pull for better at all levels.
Autonomous & Preventive Maintenance: Rolled out TPM pillars including Autonomous Maintenance and machine-level ownership restoring and maintaining basic conditions of equipment.
Machine Capability Improvement: Improved equipment reliability through Total Productive Maintenance (TPM), and mapping the key points to revamp equipment , enhancing tools and process sequences.
Customer Audit Readiness: Elevated audit performance via standardized work, traceability systems, and error-proofing (Poka Yoke), delighting customers with readiness and reliability.
Kaizen Culture: Cultivated daily improvement routines (3S), team-led Kaizens, video-based sharing of improvements, and peer recognition—creating a pull for better at all levels.

Results:

OEE improved from 35% → 68%
Process capability (Cpk) on critical lines moved to >1.33
Recordable accidents reduced to 0 in the past 12 months
Turnover dropped by 60%, with stable workforce engagement
Delivery time reduced from 3 months → 14 days
Quality claims dropped to 0, with only $120K in minor dissatisfaction reported
Company exited customer surveillance, regained preferred supplier status
$1.2M in savings from rework, claims, and downtime
Achieved $13M EBITDA from $90M in revenue (14.4% margin).

Client Testimonials

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