Case Study 1

$136MM Actual Annual EBITDA Improvement
 

Six manufacturing units. One overlooked constraint. $110MM in additional annual earnings.
 

While leading the transformation of a world-scale Canadian polyethylene manufacturer, I facilitated a two-day Value Stream Mapping session that exposed a critical raw material supply constraint limiting production across six manufacturing units.

The required ethylene was available, but an unrelated legal dispute had prevented the organization from pursuing the supply opportunity.

By challenging that assumption and bringing legal and procurement into the discussion, we secured an agreement to obtain the additional feedstock within a single day.
 

The actual financial results:
 

• $110MM in additional annual EBITDA from unlocking existing manufacturing capacity.

• $26MM in additional annual EBITDA from other operational improvements.

• $136MM total actual annual EBITDA improvement.
   

No major capital expansion required to unlock the additional capacity.
 

The breakthrough wasn't new equipment. It was challenging an assumption that nobody had questioned.