BTO (Build-To-Order) to Customer Factory

When a major direct selling company sought ways to improve efficiences, systems velocity and refocus their resources on design, development and marketing, they turned to Zoyto.

The Results?

• Improved systems velocity within their company
• Systems line throughput increased 42%
• Bottlenecks removed (i.e. accessory boxing & packout)
• Virtually eliminated line-down events due to boxing shortages/issues
• Space accumulation –Net space reduction of 21,000 sq ft.
• Refocus operational resources on design and development while Zoyto focused on planning, procurement, engineering, manufacturing, direct labor, management
• Improved hardware & accessory kitting build process dramatically

Velocity:                    Pre-Zoyto       <250 UPH                                       Currently      >400 UPH
Inventory:                   Pre-Zoyto       >30 days DSI                                  Currently      <10 days DSI
Quality:                      Pre-Zoyto       >1100 DPPM                                  Currently      <100 DPPM
Cost:                Materials Savings      21% in 2009 ( Zoyto AVL)      Total Cost Savings    12% in 2009