case study examples manufacturing

• Diversitech Team
• Mar 7, 2022

15 Sustainable Manufacturing Examples and Case Studies

Updated: Nov 17, 2023

The environment and society are intricately linked. This is something that companies have come to realize, with many now making efforts towards sustainable manufacturing as a way of ensuring both cost efficiency while meeting expectations from customers or investors alike, and local communities that could be impacted.

The environmental and economic benefits of green growth are becoming more well-known, with many businesses already taking important steps towards it. Their pioneering experiences show that this can go hand in hand for profitability as well as sustainability.

Here are 8 reasons why big brands are moving towards sustainable products

Sustainable Manufacturing Case Studies

Sustainability is the future , but many businesses have not yet leapt into this new era. They may be struggling with their short-term survival or cost pressure from clients and lack of knowledge on how best to invest in environmental improvement. It can also simply seem like an overwhelming task for those who are just starting out.

Related Article: Case Study: Taking Advantage of ODM Manufacturing

Here are some examples and brief case studies which will help show how this new approach has helped businesses save money in addition to improving their products or operations.

1. Gairdin: Manufactures sustainable gardening tools and pots

Gairdín, pronounced “Gar-Jean”, is the Gaelic Irish word for garden. They specialise in garden tools that are environmentally friendly, made from recycled and sustainable raw materials like Ocean-Bound Plastics and Algae-Blended Resin. Gairdin are a division of Diversitech Global comprising 20 years of industrial expertise in product design, manufacture and packaging. Find originality and innovation with sustainable materials always top-most in mind.

Related Article: 7 Sustainable Gardening Practices for Environmentally Conscious Individuals

2. Electrolux, Kinston Plant: Reduced energy cnsumption

The Electrolux Green Spirit program made an impactful approach to reducing energy consumption and environmental impact. Their Kinston factory achieved this by running the processes as efficiently as possible, switching off all equipment when not in use, lowering the plant's demand for compressed air and installing motion sensors for lighting. And engaged engineering and maintenance personnel to find and repair a compressed air leak every day.

3. Advanced Composite Structure: Eliminated excess raw material usage

Using lean manufacturing and a value mapping process, their production processes and the layout of the company’s production area were analyzed and reviewed. They eliminated excess movement, materials, and extra tooling to help create a more streamlined product flow. The company reduced costs by 65%, increased production from 20 units per shift to 45 units per shift, reduced its production facility size by 73%, and reduced scrap rates from 24% to 1.8%.

4. Guardian Automotive: Implemented a waste recycling program

Guardian Automotive is committed to reducing its environmental footprint. They have implemented a waste reduction program for them not only to be sustainable but also more efficient with resources. The company is now recycling among other materials unused glass cullet, fiberglass and scrap polyvinyl chloride. In 2005, the Ligonier Plant recycled more than 13,000 tons of waste and saved over $360,000.

5. Custom Print: Reduced its chemical inventory

When an investigation into the company’s chemical inventory and purchasing records revealed over 80 different chemicals on-site, a team from press operators to maintenance personnel got together for some brainstorming sessions to reduce inventory. Wasted ink was reduced by training employees to mix speciality colors from existing ink stocks. Furthermore, they came up with suggestions like modifying ventilation and air-conditioning efficiency to help improve worker health as well as greatly reduce energy costs.

6. Chrome Deposit Corporation: Cut down natural gas consumption

To increase energy efficiency and improve their responsible business practices, Chrome Deposit Corporation embarked on an effort to develop new ways of doing things. By making simple changes like adjusting boiler settings and repairing minor gas line leakages, the company was able to cut its natural gas consumption by 12%. They also purchased two chillers which implemented a closed loop system for water use. This resulted in an 85% reduction in water usage.

7. Kennecott Utah Copper Refinery: Improved power grid efficiency

Kennecott Utah has improved the energy efficiency of its refinery through the installation of a combined heat and power system. Their 6-megawatt system replaced power purchased from the coal-powered grid. It supplies more than half of the refinery’s total electricity needs and waste heat is recycled to make steam for turbines. Among deep reductions in emitted pollutants, CO2 emissions were reduced by 36,000 tonnes.

8. Besam North America: Improved energy and waste handling

With serious consultation and recommendations, Besam targeted energy, waste, and productivity surveys. This included replacing metal halide lighting with fluorescent fixtures with occupancy sensors, installation of high-efficiency lamps and electronic ballasts, reducing compressor air pressure, and repair of compressed air leaks

9. Rapid-Line: Sustainable operations to reduce its natural gas usage

Rapid-Line which fabricates and tooling for the manufacturing industry was experiencing a significant increase in their natural gas costs. Also, one of their customers encouraged them to get more involved with green practices. A new installation of ceiling fans and baffles made for better heating and cooling. Extra insulation, automated controls and reusing excess heat from the paint-line ovens boosted efficiencies and eliminated external furnace heating.

10. Isothane: Replaced hazardous raw materials with sustainable alternatives

Isothane manufactures chemical products used for insulating and protecting constructions, buildings and civil engineering structures. New government legislation had been introduced with strict emission standards and to comply with flameproof manufacturing and storage standards. They spent two months researching less hazardous and flammable chemical alternatives. Substitute materials were found and old lines were discontinued. Solvent material use was greatly decreased and much less hazardous material was stored on-site.

11. Wausau Tile: Used recycled glass chip as raw material

Wausau Tile wanted to save money and use less natural raw materials while being environmentally conscious. The company believed that by using post-consumer/industrial glass chips, which is difficult and expensive to recycle, they could reduce their environmental impact and attract new customers with their decorative value. With the use of large glass chip aggregate, they were able to make their products attractive and architecturally pleasing, and have introduced it across whole product lines.

12. Calstone: Sustainable furniture production

The company found that it could expand its market by selling more environmentally sustainable furniture products. Major changes were brought to its manufacturing plant. A vapour spray system reduced degreasing agents used on metal components. A 2000 gallon water tank reuses water for cooling equipment, and rainwater is collected for toilet flushing. Installed skylights brought in natural light for the benefit of indoor foliage plants that purify the indoor air. The company buys electricity from a hydro and wind power provider and has installed solar panels on the roof.

13. PortionPac Chemical Corporation: Products assessment based on green standards

Intending to become more sustainable, the company began an assessment on its products and obtained third-party green certification for all floor cleaners, all-purpose cleaners, glass cleaners and bowl cleaners. Also, by updating packaging components, they reduced waste, disposal costs and shipping. In addition, they also found a buyer for one of their by-product materials. These steps made PortionPac attractive to large businesses, schools and hospitals as they had the sustainability credentials along with their potential for saving costs

14. S.C. Johnson: Reduced environmental effects of its ingredients

In order to continue producing high-quality products with an environmentally-friendly mindset, S.C Johnson has developed their Greenlist system which ranks the environmental and health effects of ingredients used in its manufacturing process leading to the reformulation of many old favorites. After reviewing Saran Wrap usage, the company eliminated 4 million pounds of PVDC and reduced 1.8 million pounds of volatile organic compounds from its famous Windex product.

15. Honda: Reduced scarce material usage

Honda is serious about sustainability. They have a Green Path program that targets reductions in the use of materials and scarce resources, developing products that are easier to recycle, and reduced water waste as well CO2 emissions during manufacture. Honda uses wind turbines at its Ohio plant to generate 10,000-megawatt hours of electricity per year. It also moves 80% of vehicles from plant to dealership by train, which has reduced CO2 emissions by over 60%.

So, what does this mean for sustainable manufacturers? It means that making a switch to producing sustainable products is not only the best thing to do for the environment, but it’s also a wise business decision. Consumers are more interested than ever in buying sustainable products and that trend is only going to continue.

Making the switch to sustainable manufacturing may seem daunting, but it’s important to remember that you’re not alone. There are plenty of resources and support systems in place to help you get started. And the best part is, making the right choice for your business and the environment can also be good for you.

See our article: Is it Really cheaper to manufacture in China

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20 Manufacturing Case Studies [2024]

In this collection of 20 manufacturing case studies, we explore a variety of industries embracing technological innovation, sustainability, and efficiency to tackle modern challenges. These examples showcase how global leaders have successfully implemented groundbreaking strategies to enhance their processes, reduce environmental impact, and remain competitive in the ever-evolving market landscape.

20 Manufacturing Case Studies

Case study 1: ford motor company – implementation of 3d printing.

Company Overview:  Ford Motor Company, a giant in the automotive industry, has been exploring cutting-edge technologies to better its manufacturing procedure and development.  

Challenges:

1. Need for faster prototyping to accelerate product development.

2. Reduction of waste and costs in the manufacturing procedure.  

Solutions Implemented:  Ford integrated 3D printing technology into its manufacturing and prototyping processes. This technology allows for quickly creating parts and tools at a significantly lower cost than traditional methods.  

Results:  3D printing enabled Ford to drastically reduce the turnaround time for prototyping from months to days, accelerating the overall time to market for new vehicle designs. This approach also minimized waste and reduced the costs associated with manufacturing prototypes and certain parts, enhancing sustainability and efficiency.

Case Study 2: Patagonia – Leading Sustainability in Textile Manufacturing

Company Overview:  Patagonia, a prominent clothing label, is celebrated for its commitment to ethical manufacturing and sustainable practices.  

1. High environmental impact of traditional textile production processes.

2. Client demand for sustainable and ethically created items.  

Solutions Implemented:  Patagonia adopted organic cotton and recycled materials for its products, emphasizing sustainability throughout its supply chain. The company also implemented the Worn Wear program, encouraging consumers to repair and reuse their gear instead of buying new.  

Results:  These initiatives have significantly reduced the company’s carbon footprint and water usage, aligning with its mission to cause no unnecessary harm. Patagonia’s commitment to sustainability has improved its brand, drawing an increasing number of environmentally aware consumers.

Case Study 3: Siemens AG – Digital Factory Initiatives

Company Overview:  Siemens AG, a global electronics and electrical engineering leader, operates across the industry, power, and healthcare sectors. The company is at the forefront of industrial automation and digitalization.  

1. Increasing production efficiency and flexibility in a rapidly changing technological landscape is necessary.

2. Reducing the carbon footprint of manufacturing processes.  

Solutions Implemented:  Siemens launched its Digital Factory initiatives, which include using digital twins, automation with AI, and integration of IoT devices across its manufacturing operations. These technologies enable virtual testing and optimization before physical processes occur.  

Results:  Implementing these digital solutions has significantly enhanced the efficiency and precision of Siemens’ manufacturing methods. The digital twin technology, in particular, has led to a 30% decrease in time-to-market for new products, improved system performance, and reduced energy consumption across various facilities.

Related: Career in Manufacturing vs Service Industry

Case Study 4: Toyota Motor Corporation – Sustainable Plant Initiatives

Company Overview:  Toyota Motor Corporation is known for its innovative approaches to manufacturing and is a pioneer in producing energy-efficient vehicles, including the Prius hybrid.  

1. Maintaining leadership in automotive innovation while lessening the environmental influence of manufacturing processes.

2. Implementing measures to conserve water, reduce waste, and cut energy use.  

Solutions Implemented:  Toyota has invested heavily in building sustainable plants. One of its notable initiatives is the use of bioenergy and hydrogen fuel cells for energy. The company has also established comprehensive recycling programs and extensively utilizes solar panels across its plants.

Results:  These sustainability efforts have allowed Toyota to reduce its waste and energy consumption drastically. Using renewable energy sources in its plants has significantly cut carbon emissions. Toyota’s commitment to sustainability has improved its environmental footprint and positioned it as a leader in sustainable manufacturing practices.

Case Study 5: Boeing – Lean Manufacturing and Automation

Company Overview:  Boeing, one of the largest aerospace companies globally, manufactures commercial jetliners as well as defense, space, and security systems. Boeing is known for its high standards in manufacturing efficiency and innovation.  

1. There is a need for high efficiency and precision in aircraft production, which are complex assemblies with tens of thousands of parts.

2. Minimizing production time and cost while maintaining the highest levels of quality and safety.  

Solutions Implemented:  Boeing has embraced lean manufacturing techniques and advanced automation in its production lines. This includes using automated guided vehicles (AGVs) to move parts within the factory, automated drilling and riveting systems, and advanced robotics for assembly processes.  

Results:  The adoption of these technologies and practices has led to significant improvements in Boeing’s production efficiency. Automation has reduced the time required for assembly processes by about 25%, and lean manufacturing techniques have minimized waste and optimized the use of resources across Boeing’s production facilities. Additionally, these advancements have contributed to maintaining high safety and quality standards, which are critical in aerospace manufacturing.

Case Study 6: Intel Corporation – Advanced Chip Manufacturing

Company Overview:  Intel, a semiconductor industry leader, manufactures microprocessors central to many computing devices. The company is known for its technological innovations and large-scale manufacturing capabilities.  

1. The need to continually push the boundaries of chip performance and energy efficiency.

2. Managing the complexities and cost of ultra-precision manufacturing processes.  

Solutions Implemented:  Intel has pioneered the development of next-generation microprocessors using advanced manufacturing techniques, including photolithography and 3D transistor technology. The company invested heavily in state-of-the-art fabrication facilities with clean rooms and automated assembly lines to control the manufacturing environment precisely.  

Results:  These investments and innovations have allowed Intel to produce reduced, more powerful, and energy-efficient chips. This progress has kept Intel at the forefront of the semiconductor industry, maintaining its competitive edge and responding effectively to the rapidly evolving demands of global markets.

Related: High Paying Jobs in Manufacturing Industry

Case Study 7: BASF SE – Resource-Efficient Chemical Production

Company Overview:  BASF, one of the world’s leading chemical companies, is involved in various products, including chemicals, plastics, implementation products, farming solutions, and oil and gas.  

1. Reducing energy consumption and environmental impact in chemical production traditionally involves high energy and resource usage.

2. Ensuring sustainable growth and compliance with increasingly stringent global environmental regulations.  

Solutions Implemented:  BASF has implemented a “Verbund” system in its operations, integrating energy and material flows across different production units to maximize efficiency and minimize waste. The company also uses advanced catalysts and other innovative technologies to enhance the efficiency of chemical reactions, reducing the need for energy and raw materials.  

Results:  The Verbund system has significantly reduced energy use and greenhouse gas emissions. BASF has reported that this system saves the company approximately 19 million MWh of energy annually, equivalent to the energy consumption of a small city. These efforts have improved BASF’s environmental footprint and strengthened its position as a leader in sustainable chemical production.

Case Study 8: Coca-Cola – Water Replenishment and Recycling Initiatives

Company Overview:  Coca-Cola, one of the largest beverage companies globally, produces and distributes a variety of soft drinks and other beverages. Given the scale of its operations, sustainable water use is a critical focus for the company.  

1. Significant water usage in beverage production, coupled with growing environmental concerns.

2. The need to balance high production volumes with sustainability commitments.  

Solutions Implemented:  Coca-Cola launched comprehensive water stewardship initiatives, including advanced water treatment and recycling technologies to ensure water used in manufacturing processes is returned to the environment safely. The company also invested in community-based partnerships to replenish water in stressed areas.

Results:  Through these initiatives, Coca-Cola has achieved its goal of replenishing 100% of the water it uses in its finished products. This milestone underscores its commitment to sustainable water use. These efforts have helped mitigate the environmental impact, improved community relations, and supported regulatory compliance.

Case Study 9: Caterpillar – Automation and Connectivity in Machinery Manufacturing

Company Overview:  Caterpillar is a leading construction and mining equipment manufacturer known for its heavy machinery and engines. The company is focused on enhancing product quality and operational efficiency.  

1. High variability in product demand requires flexible manufacturing processes.

2. The must improve production efficiency and reduce operational costs.

  Solutions Implemented:  Caterpillar has embraced Industry 4.0 technologies, incorporating automation, machine learning, and IoT connectivity in its manufacturing operations. This includes using autonomous robots for material handling and assembly, sensors, and data analytics to predict maintenance needs and optimize production schedules.  

Results:  The integration of these technologies has significantly increased Caterpillar’s manufacturing agility and efficiency. Automation has reduced labor costs and improved safety by taking over dangerous tasks previously handled by humans. Moreover, connectivity solutions have enabled real-time monitoring and adjustments, leading to better product quality and faster response times to market changes.

Related: Marketing for the Manufacturing Sector

Case Study 10: Airbus – Implementing Eco-Efficient Manufacturing

Company Overview:  Airbus is a global leader in aerospace and defense, known for its commercial aircraft, helicopters, military transports, and space systems. Sustainability and innovation are key pillars of its business strategy.  

1. The aerospace industry has a significant environmental footprint, particularly in carbon emissions and resource consumption.

2. Increasing regulatory and consumer pressure to reduce environmental impact.  

Solutions Implemented:  Airbus has implemented several eco-efficient manufacturing techniques, such as using lighter and more sustainable materials, including composites that reduce the overall weight of aircraft. The company has also integrated more efficient manufacturing processes that reduce waste and energy consumption.

Results:  These initiatives have enabled Airbus to decrease fuel consumption and CO2 emissions, contributing to more sustainable flight operations. The use of advanced materials and technologies has also reduced the lifecycle environmental impact of its products, helping Airbus meet its sustainability goals and regulatory requirements.

Case Study 11: Samsung Electronics – Smart Factory Solutions

Company Overview:  Samsung Electronics, a major global player in consumer electronics and semiconductor manufacturing, strives for high efficiency and innovation in its production processes.  

1. High competition in the electronics market requires rapid adaptation to changing consumer demands.

2. Need for high efficiency and precision in manufacturing small, complex electronics components.  

Solutions Implemented:  Samsung has developed and implemented “Smart Factory” solutions across its manufacturing facilities. These include automation, AI, and IoT technologies that streamline production processes, enhance quality control, and reduce production times. For instance, automated assembly lines and AI-driven defect detection systems have improved production yield and efficiency.  

Results:  The Smart Factory initiatives have significantly improved production speed and quality while reducing manufacturing costs. By minimizing human error and optimizing production workflows, Samsung has maintained its position as a leader in the highly competitive and rapidly evolving tech industry.

Case Study 12: Tata Steel – Advanced Manufacturing and Sustainability Initiatives

Company Overview:  Tata Steel, one of the world’s leading steel producers, is based in India and operates globally. The company is committed to innovation and sustainability in its operations.  

1. High energy usage and CO2 emissions associated with steel production.

2. Increasing global demand for sustainable building materials.  

Solutions Implemented:  Tata Steel has invested in cutting-edge technologies to enhance the efficiency of its production processes and reduce its environmental impact. These include using electric arc furnaces powered by renewable energy and advanced smelting techniques that significantly lower CO2 emissions. The company also focuses on recycling scrap steel, decreasing the requirement for raw materials, and minimizing waste.  

Results:  These sustainable practices have significantly reduced Tata Steel’s carbon footprint while maintaining production efficiency. Adopting electric arc furnaces and recycling initiatives has positioned Tata Steel as a leader in sustainable steel manufacturing, appealing to environmentally conscious consumers and businesses.

Related: How to Start a Career in the Manufacturing Industry?

Case Study 13: Pfizer – Digital Integration in Pharmaceutical Manufacturing

Company Overview:  Pfizer is a global pharmaceutical giant known for its research and development in medicine. The company focuses on innovation to improve healthcare outcomes worldwide.  

1. The need for stringent quality control and efficiency in the production of pharmaceuticals.

2. Rapid scaling of production capacities, especially highlighted by the COVID-19 vaccine rollout.  

Solutions Implemented:  Pfizer has embraced digital integration within its manufacturing processes, employing technologies such as data analytics, AI, and IoT to monitor production quality and streamline operations. For instance, during the production of the COVID-19 vaccine, Pfizer utilized advanced data systems to optimize the manufacturing and distribution process, ensuring rapid delivery and high-quality standards.  

Results:  The integration of these digital technologies enabled Pfizer to enhance its manufacturing agility and quality control, dramatically speeding up the production and distribution of the COVID-19 vaccine. This approach helped meet global demand swiftly and ensured that the vaccines distributed met the highest quality standards.

Case Study 14: H&M Group – Sustainable Textile Production

Company Overview:  H&M Group, a leading global fashion retailer, is committed to sustainable fashion, aiming to become fully circular and climate-positive.  

1. The fashion industry is among the largest polluters globally, primarily due to high water usage, chemical dyes, and textile waste.

2. Consumer need for sustainable and ethically produced fashion is growing.  

Solutions Implemented:  H&M has implemented several sustainability initiatives, such as increasing the use of recycled and sustainably sourced materials, introducing water-efficient dyeing processes, and setting up garment collecting programs in their stores to promote recycling.  

Results:  These measures have significantly reduced H&M’s environmental impact. The company has made strides towards using 100% recycled or sustainably sourced materials by 2030. Additionally, their garment collection initiative has helped recycle thousands of tonnes of fabric, preventing waste and promoting circular fashion.

Case Study 15: Tesla, Inc. – Automation and Innovation in Electric Vehicle Manufacturing

Company Overview:  Tesla, Inc. is a leader in electric vehicle (EV) and clean energy solutions, renowned for its innovative approach to automobile manufacturing and energy solutions.  

1. Scaling production to meet the demands for electric vehicles.

2. Reducing manufacturing costs to make EVs more accessible to a broader market.  

Solutions Implemented:  Tesla has pioneered high automation in its production lines, particularly in its Gigafactories, which integrates cutting-edge robotics and artificial intelligence to streamline manufacturing processes. Tesla has also extended its battery technology to drop costs and enhance automobile efficiency.  

Results:  Tesla’s high degree of automation has drastically reduced the time and cost associated with vehicle assembly, allowing the company to scale up production rapidly. Innovations such as introducing more efficient battery cells have not only enhanced vehicle performance but have also lowered the cost of EVs, facilitating broader market adoption.

Related: Digital Transformation in the Manufacturing Sector

Case Study 16: Procter & Gamble (P&G) – Zero Manufacturing Waste

Company Overview:  Procter & Gamble, a multinational consumer goods corporation, manufactures various products, including personal health/consumer health and hygiene products.  

1. Significant environmental impact due to waste generated from large-scale production processes.

2. Increasing regulatory and consumer pressure for sustainable practices.  

Solutions Implemented:  P&G initiated a zero manufacturing waste program to have no manufacturing waste go to landfills. The company optimized its resource use and improved its recycling, reuse, and conversion practices, including converting waste to energy.

Results:  The initiative eliminated manufacturing waste across all its global plants, significantly reducing P&G’s environmental footprint and operational costs. This accomplishment has further bolstered P&G’s standing as a leader in sustainable manufacturing.

Case Study 17: General Electric (GE) – Advanced Additive Manufacturing

Company Overview:  General Electric, a multinational conglomerate, functions in the power, renewable energy, aviation, and healthcare sectors. GE has been at the forefront of industrial innovation.  

1. Need to enhance product performance and reduce production costs in highly competitive sectors.

2. Accelerate the development cycle of complex products.  

Solutions Implemented:  GE has aggressively invested in additive manufacturing (3D printing), particularly for producing parts for its aviation and healthcare equipment. This technology allows for lighter, more efficient designs and drastically reduces material waste.  

Results:  Additive manufacturing has enabled GE to produce parts that are impossible to make with traditional methods, reducing the weight of some components by up to 80% and overall production times by 50%. This has led to cost savings and improved product performance, particularly in jet engines and medical imaging devices.

Case Study 18: IKEA – Sustainable Furniture Manufacturing

Company Overview:  IKEA, a global furniture and home accessories leader, is known for its affordable and innovative products. The company is committed to positive environmental practices.  

1. The environmental impact of logging and furniture manufacturing.

2. Consumer demand for sustainably sourced and produced furniture.  

Solutions Implemented:  IKEA has focused on using sustainable materials such as bamboo, recycled wood, and plastics. It has also implemented more efficient manufacturing processes to reduce waste and energy consumption, including flat-pack designs that optimize transport efficiency.

  Results:  These practices have significantly reduced IKEA’s carbon footprint and made its operations more sustainable. Using recycled materials has reduced waste and appealed to environmentally conscious consumers, enhancing IKEA’s market reach and brand loyalty.

Related: AI in Chip Manufacturing Use Cases

Case Study 19: Nestlé – Water Efficiency in Food Production

Company Overview:  Nestlé, one of the world’s largest food and beverage companies, has a broad portfolio that includes dairy products, coffee, water, and pet care.

  Challenges:

1. High water usage in food and beverage production.

2. Growing global pressure to adopt sustainable water management techniques.  

Solutions Implemented:  Nestlé has focused on water stewardship, implementing advanced water recycling and reduction techniques across its factories worldwide. The company has invested in technology that treats and reuses water from manufacturing processes.  

Results:  These measures have drastically reduced Nestlé’s water consumption per ton of product, helping the company achieve significant water savings and reducing its overall environmental impact. Nestlé’s commitment to water efficiency has improved its sustainability credentials and compliance with international environmental standards.

Case Study 20: John Deere – Precision Agriculture Manufacturing

Company Overview:  John Deere, a leading agricultural machinery manufacturer, also focuses on technology solutions to improve farm productivity and sustainability.  

1. Increasing demand for agricultural efficiency and sustainability.

2. Farmers need tools that reduce costs and increase crop yield.  

Solutions Implemented:  John Deere has incorporated advanced technologies into its equipment, such as GPS tracking, IoT connectivity, and data analytics, to facilitate precision farming. These technologies allow for better resource management, optimizing everything from seeding to harvesting.

Results:  Adopting these technologies has enabled farmers to significantly increase efficiency and reduce waste, leading to better yields and lower environmental impact. John Deere’s creations have cemented its leadership in the farming sector, proposing cutting-edge resolutions catering to current farmers’ requirements.

These 20 case studies demonstrate the transformative power of innovation in manufacturing across diverse sectors. By adopting advanced technologies and sustainable practices, these companies have optimized their operations and set new standards for environmental responsibility and operational excellence. Their success stories offer inspiration for future industry advancements.

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Design for Manufacturing Examples: Real-Life Engineering Case Studies

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Sustainable manufacturing success stories: real world examples of positive impact.

Reading time 11 mins

• Sustainable manufacturing is the practice of producing goods in an environmentally responsible and resource-efficient manner.
• A significant percentage of business leaders view sustainability as a costly obligation as opposed to an investment in the future.
• However, by implementing sustainable design principles from the initial concept stages, companies reap numerous benefits in the present.
• Key advantages of sustainable manufacturing: Less harmful environmental impact, cost savings, resource efficiency, competitive advantage, and consumer preference.
• Organisational barriers to a sustainable manufacturing system: initial investment, complexity, regulatory uncertainty, supply chain issues, consumer education
• Ignitec’s 10+ years of sustainable product design experience and other success stories from around the world prove that challenges and barriers can be overcome inexpensively, profitably, and quickly!

Developing a new product sustainably doesn’t cost the earth. Call us for a quote!

Ben mazur  managing director.

Last updated Oct 26, 2023

I hope you enjoy reading this post. If you would like us to develop your next product for you,  click here

S ustainable manufacturing, also known as green manufacturing or eco-friendly manufacturing, refers to the practice of producing goods in an environmentally responsible and resource-efficient manner. Examples of benefits associated with sustainable manufacturing that implement sustainable design principles from concept stages straight through to design, manufacturing, and end-of-life disposal:

• Less harmful environmental impact
• Cost savings
• Resource efficiency
• Competitive advantage
• Consumer preference

Numerous experiences at Ignitec have shown us that sustainable manufacturing and eco-friendly business practices can have tangible and diverse benefits that are inexpensive and quick to implement. Contact us for more info on sustainable product development solutions that will transform your bottom line!

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Ignitec’s environmental monitoring services, ignitec’s rapid prototyping service: quality and efficiency in one, meet our new objet260 connex 3 3d printer.

A recent report by the Capgemini Research Institute concluded that more than 51% of business leaders see sustainability as a costly obligation as opposed to an investment in the future. In this blog, we’ll look at real-world examples of sustainable manufacturing success stories that prove that positive impact can be achieved here and now without costing the earth!

10 advantages & benefits of sustainable manufacturing

Manufacturing sustainably was considered a niche not too long ago but has now become an important part of most business strategies (even if only in theory for many). However, sustainable practices are becoming more widely adopted and growing in popularity as the benefits are tangible with both short and long-term benefits.

1. Environmental Benefits

• According to the United Nations Industrial Development Organization ( UNIDO ), sustainable manufacturing applied in a circular economy can reduce carbon emissions in the manufacturing sector by up to 80%.
• A study by the World Economic Forum estimates that sustainable manufacturing practices such as green packaging (i.e. materials made from wheat and straw containing enzymes that decompose organically) can lead to a 90% reduction in water use and a 40% reduction in energy use.

2. Cost Savings

• A report by the American Sustainable Business Council in 2022 underlines that efficiency investments have reduced annual energy expenditures in the US by nearly $800 billion and reduced energy consumption per household by 16%.
• The World Bank Sustainability Review of 2021 reports that companies implementing sustainable practices can achieve a significant reduction in operational costs.

3. Resource Efficiency

• The Westminster City Council states that sustainable manufacturing leads to a reduction in solid waste which would otherwise have been designated to landfills
• Sustainable manufacturing practices can also lead to significant reductions in raw material consumption, preserving natural resources.

World Economic Forum Case Study : 3D printing builds products “from the bottom up” and therefore reduces waste, which can run up to 30 pounds of raw material per pound produced by traditional means. It also carries a cost advantage, especially when precious materials like titanium and nickel-alloy steels are involved in production. Additive manufacturing (processes that make three-dimensional products from a digital design) can reduce material costs by up to 90% and energy costs by up to 50%. By 2025, 3D printing could potentially reduce manufacturing costs by about $593 billion.

4. Competitive Advantage

• According to a survey by McKinsey & Company , 43% of respondents believe that sustainability is important for maintaining or establishing a competitive advantage.

5. Consumer Preference

• In 2022 a Statista survey found that over 80 percent of consumers in the UK would be willing to pay at least 10% more for products if the items in question were considered sustainable.

6. Regulatory Compliance

• Many governments worldwide are introducing regulations and incentives, such as the UK Government Green Financing Framework (2021), to promote sustainable manufacturing.
• Complying with these regulations can help companies avoid fines and legal issues.

7. Improved Reputation

• Sustainable manufacturing can enhance a company’s reputation and brand image.
• A joint study from McKinsey & Company and NIQ examines sales growth for products that claim to be environmentally and socially responsible

8. Employee Satisfaction

• Companies engaged in sustainable manufacturing often report higher employee satisfaction and retention rates.
• This is essential for attracting and retaining top talent.

9. Supply Chain Benefits

• Sustainable manufacturing practices can improve supply chain resilience and reduce the risk associated with resource scarcity and environmental disruptions.
• Read our tips on improving your supply chain as it relates to environmental, social, and governance impacts.

10. Innovation and Product Development

• Sustainable manufacturing encourages innovation in product design and processes, leading to new market opportunities and revenue streams.

These statistics demonstrate that sustainable manufacturing not only benefits the environment but also contributes to cost savings, increased competitiveness, and improved corporate social responsibility. As environmental concerns and regulations continue to grow, the adoption of sustainable manufacturing practices is essential for businesses in all industries.

Green manufacturing success stories from various industries around the world

Patagonia , a California-based outdoor recreation clothing company, has a long history of implementing sustainability practices into its product design and company culture – and has a string of awards (e.g. UN Champion of the Earth, Fabric of Life Award, Corporate Excellence Awards for Climate Innovation). They reduced their carbon footprint by switching to renewable energy sources, implementing fair labour practices, and launching initiatives like “Worn Wear” to encourage customers to buy used clothing.

Toyota , the Japanese multinational automotive manufacturer, adopted lean manufacturing and waste reduction practices, resulting in not only higher efficiency but also significant reductions in energy consumption and emissions. They have a demonstrable commitment to continuous improvements in sustainability: improving water usage, promoting end-of-life and recycling technologies, and societies that live in harmony with nature.

H&M , founded in Sweden in 1947, is often criticised for greenwashing and making products seem more environmentally friendly than they are. However, by publishing an annual sustainability report and continuing its efforts to reduce its environmental footprint by using sustainable materials, recycling clothing, and improving the energy efficiency of its stores and distribution centres, it has managed to maintain a dominant market position and restore its brand image.

Interface , an American modular carpet manufacturer, implemented a mission called “Mission Zero” to eliminate any negative impact on the environment and is the world’s first global flooring manufacturer to sell all products that are carbon neutral across its entire life cycle. 79% of the energy they use is from renewable sources, and their innovative manufacturing and supply chain practices have: reduced market-based greenhouse gas emissions by 97%, generated 67% less waste, and contain an average 52% of recycled or biobased materials in the products they sell.

Ignitec® , a UK design and tech consultancy founded in 2013, has a goal of reaching net-zero by 2033. Our in-house manufacturing capabilities and energy-efficient technologies, such as our 3D printer, allow for supply chain agility, significant waste reduction, substantially lower emissions and the ability to attract and retain more clients. Clearly stating our approach and expectations in our sustainability policy (e.g. recycle, switch to renewable energy, eliminate wastage, offset carbon) has improved our bottom line, reduced operational costs, and boosted team spirit.

These examples illustrate how companies in different industries have successfully integrated sustainable manufacturing practices into their operations, reducing environmental impact and often realising cost savings while maintaining or enhancing their competitiveness.

Final thoughts on manufacturing sustainably

Sustainable manufacturing is an essential strategy for businesses looking to thrive in an increasingly environmentally conscious world. While it offers numerous benefits, sustainable product design challenges and organisational barriers to a sustainable manufacturing system cannot be ignored:

• Initial investment: Transitioning to sustainable manufacturing practices may require significant upfront investments in new technologies, processes, and employee training.
• Complexity: Implementing sustainable practices can be complex and challenging, as it often involves redesigning production processes and supply chains.
• Regulatory uncertainty: Compliance with environmental regulations can be uncertain, and evolving regulations may require constant adaptation.
• Supply chain issues: Ensuring sustainability throughout the supply chain, including sourcing sustainable materials, can be complex and may involve additional costs.
• Consumer education: Consumers may still be unaware of the environmental and social impact of their consumption choices, making it challenging for sustainable products to gain market share.

The challenges are real, but the solutions are readily available. Products with purpose that do no/little harm to people or the planet are at the heart of everything we do. We’ve had over a decade of experience with designing and manufacturing products for our clients sustainably and affordably – and can do the same for you; contact us for a quote !

Sustainable design and why it matters for a net-zero future

5 ways to improve your supply chain environmental, social governance impact in 2023, 5 sustainable design challenges and how to overcome them, faq’s, why is sustainable manufacturing important for the environment.

Sustainable manufacturing is crucial for the environment because it reduces carbon emissions, conserves resources, and minimises waste, helping to combat climate change and protect ecosystems.

How can businesses transition to sustainable manufacturing practices?

Businesses can transition to sustainable manufacturing by investing in energy-efficient technologies, adopting eco-friendly materials, and implementing waste reduction strategies in their production processes.

What are some real-world examples of sustainable manufacturing success stories in the UK?

Real-world examples of sustainable manufacturing success stories in the UK include companies like Patagonia, Tesla, and Interface, which have reduced their environmental impact through innovative practices.

When did the UK government start promoting sustainable manufacturing initiatives?

The UK government has been promoting sustainable manufacturing initiatives for several years, with a growing focus on reducing carbon emissions and increasing energy efficiency.

Which industries benefit the most from sustainable manufacturing practices in the UK?

Industries that benefit significantly from sustainable manufacturing in the UK include automotive, fashion, pharmaceuticals, and consumer goods, among others.

Who regulates sustainable manufacturing practices in the UK?

Sustainable manufacturing practices in the UK are regulated by various governmental agencies and bodies, including the Environment Agency and the Department for Business, Energy & Industrial Strategy.

What are the challenges of implementing sustainable manufacturing in the UK?

Challenges of implementing sustainable manufacturing in the UK include the initial investment required, regulatory complexities, and the need to ensure sustainability across supply chains.

How do sustainable manufacturing practices impact a company's bottom line in the UK?

Sustainable manufacturing practices can positively impact a company’s bottom line in the UK by reducing operational costs, enhancing reputation, and attracting eco-conscious consumers.

Why is sustainable manufacturing considered a form of corporate social responsibility in the UK?

Sustainable manufacturing aligns with corporate social responsibility in the UK by demonstrating a company’s commitment to environmental stewardship and ethical business practices.

What role does innovation play in sustainable manufacturing in the UK?

Innovation is crucial in sustainable manufacturing in the UK as it drives the development of new eco-friendly technologies and products, contributing to long-term growth.

How do consumers in the UK influence the adoption of sustainable manufacturing?

Consumers in the UK play a vital role in driving the adoption of sustainable manufacturing by demanding eco-friendly products and supporting environmentally responsible companies.

Why is employee engagement important in sustainable manufacturing initiatives in the UK?

Employee engagement is important in the UK for sustainable manufacturing initiatives as it fosters a culture of sustainability and promotes the successful implementation of eco-friendly practices.

What are the economic benefits of sustainable manufacturing in the UK?

Economic benefits of sustainable manufacturing in the UK include cost savings through reduced energy and resource use, improved supply chain efficiency, and new market opportunities.

How can companies in the UK measure the success of their sustainable manufacturing efforts?

Companies in the UK can measure the success of their sustainable manufacturing efforts by using key performance indicators like carbon emissions reduction, waste reduction, and resource efficiency.

Why are sustainable materials crucial in the UK's sustainable manufacturing efforts?

Sustainable materials are crucial in the UK’s sustainable manufacturing efforts because they reduce the environmental impact of products and contribute to a greener supply chain.

What are the regulatory incentives for sustainable manufacturing in the UK?

In the UK, regulatory incentives for sustainable manufacturing include tax incentives, grants, and support for research and development of eco-friendly technologies.

How does sustainable manufacturing in the UK contribute to supply chain resilience?

Sustainable manufacturing in the UK enhances supply chain resilience by reducing risks associated with resource scarcity and environmental disruptions.

What are some global trends influencing sustainable manufacturing practices in the UK?

Global trends influencing sustainable manufacturing practices in the UK include circular economy principles, renewable energy adoption, and increased focus on sustainability certifications.

What is the outlook for sustainable manufacturing in the UK in the coming years?

The outlook for sustainable manufacturing in the UK is positive, with continued growth and innovation expected as companies adapt to changing consumer demands and environmental concerns.

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IoT in Manufacturing: Top Use Cases and Case Studies

Updated May 17, 2021

Within this article, we’ll be discussing practical IoT applications in manufacturing and use cases of industrial IoT technology in manufacturing

What is IoT?

What is iiot, the benefits of iot in manufacturing.

IoT represents a digital transformation in manufacturing processes and business operations. Using it alongside an advanced machine data platform can be transformational. And there are many benefits of IoT in manufacturing:

Process Optimization

Inventory Management

Predictive Maintenance

IoT in Manufacturing Use Cases [+Case Studies]

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Supply Chain Management and Optimization

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• Forecasting accuracy improvement
• Greater control of inventory

Digital Twins

Real-Time Machine Monitoring

Production visibility.

Integrating Systems

Compiling kpis.

Asset Utilization

Difficulties of Adopting IoT in Manufactur ing

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Sourcing & Supply Chain Report: Data is the New Currency

3 Examples to Reduce Your Carbon Footprint and Cut Manufacturing Costs

Key Takeaways:

• Manufacturers can veer off the path to product sustainability and profitability without the right data
• Three case study examples highlight hidden and counterintuitive opportunities to reduce product manufacturing CO2e

The Full Article:

Many manufacturers have established aggressive goals to reach net-zero emissions. Understanding how to reduce the embodied carbon in existing parts and new designs is pivotal to achieving corporate sustainability goals and addressing climate change.

To address today’s market needs, aPriori enables manufacturers to assess design and production changes across sustainability , cost , and manufacturability simultaneously. With this granular level of detail, teams can compare design, manufacturing, and sourcing options and make data-driven decisions quickly and confidently.

Fact-based insight is essential – especially because some data-driven recommendations may seem counterintuitive if detailed information isn’t available to inform decision-making.

The following three case study examples showcase the interplay between costs and carbon emissions in the discrete manufacturing industry.

Example 1: How Does Factory Location Affect Your Cost and Carbon Footprint?

A side panel for a car is currently manufactured in Eastern Europe in this first example. The sourcing team is evaluating the following locations in an effort to reduce manufacturing costs and/or carbon: China, Eastern Europe, Western Europe, and the United States. The team needs to understand the trade-offs to evaluate regional manufacturing effectively.

To evaluate its options, the sourcing team uploads the 3D CAD model of the side door panel into the aPriori digital factory and enters the following specifications:

• Material: ABS
• Production process: Plastic molding
• Annual volume: 5,000
• Production duration: Five years

The current baseline cost from Eastern Europe is $16.85 per unit and 8.3 kilograms of carbon emissions, which is evenly split between material and process CO 2 e. Now, the sourcing team compares greenhouse gas emissions (GHG emissions) across various regions.

Learn more about aPriori’s Regional Data Libraries .

Figure 1 shows the mix of energy sources, including coal, natural gas, nuclear energy, hydropower, and renewable energy in each region’s energy use. China, producing about 75% of its electricity from coal, has the highest CO 2 e emissions per kilowatt-hour. By contrast, Western Europe has the lowest emissions because its energy mix only includes 12% coal.

The carbon impact for each location varies significantly. Companies can start to make these trade-offs and better understand the strategic value of saving 1.3 kilograms of CO 2 e by moving production to the United States and increasing the production cost by nearly $4 per unit. The company can determine the best path forward based on its profitability and sustainability targets.

When considering cost and carbon using aPriori analysis, Eastern Europe is preferable to China because both the environmental impact and cost are lower. But depending on the company’s priorities, Western Europe may be the preferred production region based on its mix of cost and carbon.

Example 2: The Impact of Material Choices on Carbon Emissions

For an electric vehicle control unit connector, choosing between different materials can bring surprises in terms of carbon footprint. For the plastic housing of this assembly, the manufacturer is comparing Nylon 6 and Nylon 6 with a 30% glass fill to look at the differences between the two materials. The component assumptions and specifications are the same for each material:

• Component/CAD model: Electric vehicle control unit (EVCU) connector
• Factory location: United States

First, let’s establish a baseline to base our assumptions using data from ecoinvent, aPriori’s life cycle inventory database (LCI) / life cycle assessment (LCA) partner. LCI data shows that Nylon 6 has 9.27 CO2e per kilogram, while its glass-filled counterpart has 7.43 CO2e per kilogram – 20% less than Nylon 6, which is a much lower carbon intensity.

The product design team assumed that trying a glass-filled Nylon 6 may offer an improvement, as the glass-fill usually leads to faster cooling times, which reduces energy used during production. When you look at the data in isolation, the glass-filled nylon appears to have lower CO 2 e per kg.

However, because the material is also more dense, the same design (i.e., the same volume of material) will be heavier, so it is not an accurate apples-to-apples comparison. CO₂e by volume of material is similar for both options. But running the manufacturing process simulation through aPriori proved the design team’s assumption: the cooling time was reduced, leading to much lower process carbon but virtually identical material carbon.

Financially, this also translates to a cost reduction of about 10%, from $16.40 to $14.48. The glass-filled Nylon’s stiffer properties also allow potential design modifications, such as reducing the sidewall thickness. This could lead to less material required (less volume), and thinner walls could mean even faster injection and cooling times.

This points to the importance of iterative design processes in manufacturing. Manufacturers can make more informed and sustainable decisions by optimizing material choice and understanding its impact on both carbon emissions and costs.

Example 3: The Manufacturing Process and Carbon Implications

Finally, the third example examines the carbon emissions difference between die casting and machining. We’re using the same part in the previous example, but now we are evaluating the part’s metal component (produce 5,000 components annually for a five-year period).

Die casting for this component provides a significantly lower cost and carbon footprint. Production volume is a central factor here: it’s typically cost-prohibitive to die-cast low-volume parts. Due to the type of part and volume, it’s approximately nine times more to machine it.

The machining process also has a significantly higher CO 2 e component than die casting. Die casting is much more material efficient, so less is needed overall despite requiring more energy to melt and pour the metal versus machining, which mills out a machined part.

The biggest CO 2 e driver for this part stemmed from its material carbon. The process uses aluminum billet, which requires more processing than aluminum ingots. The biggest factor, however, is the amount of waste associated with machining, which wasted about 68% of the original aluminum stock.

With this understanding, manufacturers can consider ways to modify the product design or how the material is used in production to reduce waste. Or focus on opportunities to increase material utilization. This example shows how waste – especially with metal parts – can increase a product’s CO 2 e exponentially.

Use Insights – Not Intuition – to Reduce Your Carbon Footprint

The journey to manufacturing sustainability is rife with complexities. Real-time data is a critical element in developing an effective methodology to identify and mitigate emissions based on energy-intensive manufacturing processes and raw materials that are high in carbon But by analyzing every step of design and production, manufacturing teams can uncover opportunities to reduce costs and minimize the carbon impact during design and throughout the supply chain.

As our three case study examples indicate, detailed insight into the manufacturing design and production lifecycle is required to gather and analyze all relevant data to strike the right balance for a sustainable future. And aPriori provides real-time insights for manufacturers to evaluate, reduce, and help to report on the carbon footprint of their products.

Frost & Sullivan Names aPriori the Digital Manufacturing Solutions Leader

More Resources:

• 5 Sustainability Challenges & How to Overcome Them
• Hitting Sustainability Goals with aPriori & PTC
• The Green-Golden Ratio: How to Design for Sustainability & Profitability

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The Lean Post / Articles / Lean Management Case Studies Library

Lean Management Case Studies Library

By Chet Marchwinski

May 16, 2014

Learn how a variety of businesses and organizations used lean management principles to solve real business problems. We’ve arranged the examples in 16 categories to help you find the ones right for your environment.

Lean Management Examples from a Variety of Businesses

The following case studies of lean management principles in action show you how a variety of real businesses solved real business problems under diverse conditions.

We’ve arranged the stories in 16 categories to help you find the examples you need. There is some overlap. For instance, a “Lean Manufacturing” case study may also appear with “Privately Held Companies.”

Lean Manufacturing

• Logistics, Supply Chain, and Warehousing
• Lean Material Handling
• Job Shops (Low-volume, High-mix Manufacturing); Tool and Die
• Lean in Government
• Lean Healthcare
• Lean Accounting
• Lean Construction
• Lean in Office and Service Processes
• Lean in Education

Problem Solving

Pull Systems

Culture Change

People Development

Privately Held Companies

Maintenance

Many of the executives who took part in these transformations are interviewed in LEI’s Senior Executive Series on Lean Leadership . After reading the case studies, be sure to get their personal perspectives on leading change. (Feel free to link to this page, but please respect the copyrights of LEI and journalists by not copying the articles.)

Are you doing something new or notable in the practice of lean management? Let us share what you learned with the lean community. For more information, contact LEI’s Director of Communications Chet Marchwinski at cmarchwinski at lean dot org

Thrustmaster Turns Around

Learn how Thrustmaster of Texas successfully adopted lean thinking and practices to make sustainable improvements in a short period of time, and how other manufacturers of highly engineered, low-volume products can follow their lead using the Lean Transformation Framework.

Lean + Circular Principals = a New True North for Manufacturer

SunPower’s lean journey resembled most others until it defined a new mission, a new True North by combining lean principals with those of the “circular economy” to launch what it is calling a CLean Transformation.

Sustain Your Lean Business System with a “Golden Triangle” After a medical device maker took a hit to margins to fight off global competition, it rebuilt them by lifting its lean operating system to a higher level and keeping it there with a “golden triangle” of sustainability.

Followup Story:

Manufacturing Balancing Act: Pull Versus ERP

In this follow-up to “Sustain Your Lean Business System with a ‘Golden Triangle,’” a case study about Phase 2 Medical Manufacturing, the company needs warehouse space to keep pace with sales growth spurred by the lean transformation. Instead, it expands a pull system by connecting the plan-for-every-part database that underpins one-piece flow production with ERP, typically associated with big batch production.

Cultivating a Lean Problem-Solving Culture at O.C. Tanner If you are in the “appreciation business”, you have to live it in your own workplace. For O.C. Tanner that meant a lean transformation had to show the company appreciated and wanted people’s problem-solving ideas. Here’s a report on that effort, including what worked and what didn’t.

Lean Partnership with Dealer Network Helps Vermeer Reduce End-to-End Inventory on Top Sellers

A lean transformation had taken heavy-equipment manufacturer Vermeer away from batch manufacturing, but batch ordering by dealers was delaying how quickly they got equipment like brush chippers. Learn how it  began converting its domestic industrial-line distribution network to lean replenishment, improving service to end customers and improving cash flow for Vermeer and its dealers.

Herman Miller’s Experiment in Excellence At Herman Miller, the lean management effort helps it build problem solvers as well as world-class office furniture. And as this case study shows, lean practices also helped it weather a brutal recession.

Build Your “House” of Production on a Stable Foundation Rigorous problem solving creates basic stability in a machining intensive facility.

A Journey to Value Streams: Reorganizing Into Five Groups Drives Lean Improvements and Customer Responsiveness An approach to creating a value-stream culture centered on autonomy, entrepreneurialism, and lean principles.

Change in Implementation Approach Opens the Door at EMCO to Greater Gains in Less Time A relatively quick, intensive project accelerates the rate of improvement and creates a showcase facility for spreading lean concepts.

Creating the Course and Tools for a Lean Accounting System A lean accounting implementation fills the frustrating disconnect between shop-floor improvements and financial statements.

For Athletic Shoe Company, the Soul of Lean Management Is Problem Solving After taking a lean tools approach to change, management re-organized the transformation around problem solving and process improvement to create a culture that engaged people while boosting performance.

Knife Company Hones Competitiveness by Bucking the Status Quo An iconic family-owned company turns to lean manufacturing to reduce costs by at least 30% to keep its U.S. operations open.

Lean Transformation Lives and Dies with Tools and Dies After a failed first try at just-in-time production , a company transforms tool maintenance, design, and fabrication to create a solid foundation for a second attempt.

Seasoned Lean Effort Avoids “Flavor-of-the-Month” Pitfall A look at how one company’s approach to what new tools it introduced, in what order, and how it prevented each new technique from being viewed as a “flavor of the month” fad.

Shifting to Value-Stream Managers: a Shop-Floor Revolution Leads to a Revolution in Plant Organization

Two years into a lean transformation, the low-hanging fruit has been plucked and progress has started to slow. Read how a Thomas & Betts plant recharged the transformation and reached higher levels of performance by using value-stream managers to span functional walls.

Using Plan-Do-Check-Act as a Strategy and Tactic for Helping Suppliers Improve

At Medtronic’s Neuromodulation business unit, the plan-do-check-act cycle is used on a strategic level to guide overall strategy for selecting and developing key suppliers as well as on a tactical level for guiding lean transformations at supplier facilities.

back to top

Logistics, Supply Chain, and Warehousing How a Retailer’s Distribution Center Exemplifies the Lean Precept “Respect for People,” and Reaps the Benefits

To make sure training engaged and resonated with people after previous attempts at a lean transformation faltered, LifeWay matched lean management tools and principles to its Bible-based culture and language.

Lean management case study series: Lean in Distribution: Go to Where the Action Is!

Starting with daily management walkabouts and standard work , this distributor had laid the groundwork for steady gains for years to come, just two years after its first kaizen workshop .

Putting Lean Principles in the Warehouse

Executives at Menlo Worldwide Logistics saw an opportunity to leapfrog the competition by embracing lean in its outsourced warehousing and receiving operations.

Lean Thinking Therapy Spreads Beyond the Shop

A company expands the lean transformation from the shop floor to international distribution, domestic shipping, and product development.

Sell One, Buy One, Make One: Transforming from Conventional to Lean Distribution

Large inventories to cover fluctuations in demand once characterized Toyota’s service parts distribution system — but no more. Here’s how one DC made the switch.

Material Handling

Following Four Steps to a Lean Material-Handling System Leads to a Leap in Performance

Creating the critical Plan for Every Part was one step in a methodical four-step implementation process to replace a traditional material-handling system.

Low-volume, High-mix Manufacturing; Tool and Die

The Backbone of Lean in the Back Shops

Sikorsky managers apply the lean concept of “every part, every interval” (EPEI) to level the mix in demand and create flow through a key manufacturing cell .

Landscape Forms Cultivates Lean to Fuel Growth Goals

With single-item orders 80% of the time, a low-volume, high-mix manufacturer decided single-piece flow cells were the best way decided the best way to add new products without having to constantly reconfigure production.

Lean Transformation Lives and Dies with Tools and Dies

After a failed first try at just-in-time production, a company transforms tool maintenance, design, and fabrication to create a solid foundation for a second attempt.

Canada Post Puts Its Stamp on a Lean Transformation

The “ inventory ” of mail already is paid for, so moving it faster doesn’t improve cash flow as in lean manufacturing. But Canada Post discovered that traditional batch-and-queue postal operations could benefit from lean principles.

Lean Thinking in Government: The State of Iowa

This story examines a kaizen event at a veterans home and more broadly at the lean effort in Iowa government.

Lean Thinking Helps City of Chula Vista with Budget Crunch

Goodrich Aerostructures’ Chula Vista plant introduces city government to lean thinking and practices so in order to maintain municipal services without resorting to further cuts in the workforce.

Using Lean Thinking to Reinvent City Government

Grand Rapids, MI, turns to lean principles to consolidate operations, eliminate wasted time and effort, and streamline to improve productivity while providing the quality of service that residents want.

Transforming Healthcare: What Matters Most? How the Cleveland Clinic Is Cultivating a Problem-Solving Mindset and Building a Culture of Improvement

The Cleveland Clinic reinvents its continuous improvement program to instill a problem-solving mindset and the skillset to solve everyday problems among the clinic’s thousands of caregivers.

View from the Hospital Floor: How to Build a Culture of Improvement One Unit at a Time

In order to do more and improve faster, the Cleveland Clinic is rolling out a methodology for building a “culture of improvement” across the 48,000-employee hospital system as this followup to the above story shows. Here’s how it works according to the people making the changes.

Dentist Drills Down to the Root Causes of Office Waste

Dentistry is a job shop that Dr. Sami Bahri is out to improve fundamentally for the benefit of patients through the application of lean principles.

Lean management case study series: Pediatric Hospital in Tough Market Pegs Growth to Lean Process Improvement

Lean improvement projects at Akron Children’s Hospital have saved millions of dollars, increased utilization of expensive assets, and reduced wait times for patients and their families.

Lean Design and Construction Project an Extension of Lean Commitment at Akron Children’s Hospital

Input from nurses, doctors, therapists, technicians, and patient parents heavily influenced design decisions..

“Pulling” Lean Through a Hospital

A thoughtful rollout of lean principles in the ER and eye-opening results created a “pull” for lean from other departments.

Best in Healthcare Getting Better with Lean

Mayo Clinic, Rochester, MN, stresses to doctors that the lean effort is aimed not at changing the moment of care, the touch moment between doctor and patient, but the 95% of the time when the patient is not in the doctor’s office

Fighting Cancer with Linear Accelerators and Accelerated Processes

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Physicians and staff have tirelessly reengineer processes and patient flow to eliminate as much waiting and waste as possible.

The Anatomy of Innovation

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leveraging Lean to Get the Oil Out

Aera Energy LLC, a California oil and gas company,  relies on lean principles to improve key processes, including drilling new wells, repairing existing ones, and maximizing the number of barrels of crude pumped each day.

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Columbus, OH, public schools, experiment with lean tools and process thinking to remove wasteful activities that don’t help them help students learn.

Lean Inroads into Alabama Academia

How the University of Alabama in Huntsville integrated lean concepts throughout its industrial engineering curriculum.

Linking Lean Thinking to the Classroom

Value-stream mapping is one of many activities included in the Ford Partnership for Advanced Studies (Ford PAS), an academic program designed to link high-school classroom learning to the skills needed in college and business.

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For Athletic Shoe Company, the Soul of Lean Management Is Problem Solving

After talking a lean tools approach to change, management re-organized the transformation around problem solving and process improvement to create a culture that engaged people while boosting performance.

Toothbrush Plant Reverses Decay in Competitiveness

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Sustain Your Lean Business System with a “Golden Triangle”

After a medical device maker took a hit to margins to fight off global competition, it rebuilt them by lifting its lean operating system to a higher level and keeping it there with a “golden triangle” of sustainability. You’ll recognize two elements of the triangle right away: visual control and standardized work . The third, accountability management or a kamishibai system, is probably less well known but just as critical.

Cultivating a Lean Problem-Solving Culture at O.C. Tanner

If you are in the “appreciation business”, you have to live it in your own workplace. For O.C. Tanner that meant a lean transformation had to show the company appreciated and wanted people’s problem-solving ideas. Here’s a report on that effort, including what worked and what didn’t.

Lean Thinking in Aircraft Repair and Maintenance Takes Wing at FedEx Express

A major check that used to take 32,715 man-hours was cut to 21,535 hours in six months. That translated into a $2 million savings, which dovetailed with the company’s emphasis on reducing costs during the recession.

Construction

Input from nurses, doctors, therapists, technicians, and patient parents heavily influenced design decisions—from incorporating emergency room hallways that protect the privacy of abused children to the number of electrical outlets in each neonatal intensive care room.

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About Chet Marchwinski

Chet has been a humble, unwashed scribe of the lean continuous improvement movement since books by Taiichi Ohno and Shigeo Shingo first hit North America in the 1980s. At LEI, he contributes to content creation, marketing, public relations, and social media. Previously, he also wrote case studies on lean management implementations in…

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Lean Six Sigma: A DMAIC Case Study Example in Manufacturing

Introduction to Lean Six Sigma in Manufacturing

Lean Six Sigma is a synergistic business improvement methodology that focuses on reducing waste and variability in processes to enhance overall performance. In the manufacturing sector, it plays a pivotal role in streamlining operations, improving quality, and reducing costs.

What is Lean Six Sigma?

Lean Six Sigma combines the waste-reduction principles of Lean manufacturing with the process improvement tools of Six Sigma. The aim is to create a more efficient and error-free production process. Lean Six Sigma is data-driven and focuses on customer satisfaction as its ultimate goal. It seeks to eliminate defects, overproduction, waiting times, non-utilized talent, transportation, inventory excess, motion waste, and extra-processing.

The Significance of DMAIC in Process Improvement

DMAIC stands for Define, Measure, Analyze, Improve, and Control. It is a structured, phase-driven approach that guides teams through the process of identifying problems, measuring key aspects of the current process, analyzing data, improving, and controlling future process performance.

The significance of DMAIC in process improvement, especially in manufacturing, cannot be overstated. It provides a standardized and systematic approach to problem-solving, which leads to significant improvements in efficiency, productivity, and quality. Following the DMAIC model helps ensure that process enhancements are based on reliable data and that improvements are sustainable over the long term.

To delve deeper into each phase of the DMAIC model and how it can be applied in manufacturing, please refer to the following resources:

• DMAIC process steps
• DMAIC roadmap for manufacturing
• DMAIC methodology in manufacturing

For practical insights and guidance, manufacturing managers can explore:

• DMAIC checklist for manufacturing projects
• DMAIC project examples in manufacturing
• DMAIC implementation in manufacturing industry

By incorporating DMAIC into their process improvement initiatives, manufacturing managers can gain a clearer understanding of their operations, identify areas for enhancement, and embark on a path to excellence with a structured approach to continuous improvement.

The DMAIC Model Explained

Lean Six Sigma is a collaborative team effort that seeks to improve performance by systematically removing waste and reducing variation. The DMAIC model stands at the core of Lean Six Sigma, providing a structured approach for process improvement in manufacturing. Let’s walk through each phase of the DMAIC model, which is a cornerstone of a dmaic case study in manufacturing .

Define Phase – Identifying the Problem

In the Define phase, the focus is on clarifying the problem, defining the project goals, and identifying the customer requirements. It sets the stage for the entire project by establishing the scope and objectives.

• Establish the project scope and objectives.
• Identify the internal and external customers and their requirements.
• Develop a problem statement and project charter.

Measure Phase – Gathering Data

The Measure phase involves data collection to establish baselines and understand current process performance. This phase is crucial for comparing pre-improvement and post-improvement results.

• Determine what needs to be measured and how to measure it.
• Collect data to establish a baseline for the process performance.
• Validate the measurement system to ensure the reliability of data.

Analyze Phase – Identifying Root Causes

During the Analyze phase, the aim is to identify the root causes of the problem. This involves analyzing the data collected in the Measure phase to determine the factors that are impacting process performance.

• Use data analysis to identify patterns, trends, and correlations.
• Perform root cause analysis to pinpoint the underlying causes of defects or inefficiencies.
• Validate root causes through further data collection and analysis if necessary.

Improve Phase – Implementing Solutions

The Improve phase focuses on developing and implementing solutions to address the root causes identified in the Analyze phase. This may involve making changes to processes, redesigning products, or introducing new technologies.

• Brainstorm potential solutions and select the most effective ones to implement.
• Conduct pilot tests to ensure the solutions achieve the desired improvement.
• Implement the solutions and monitor their impact on process performance.

Control Phase – Sustaining Improvements

The final phase, Control, ensures that the improvements are sustained over time. This involves putting systems in place to monitor the process and prevent it from reverting to its previous state.

• Develop a control plan to monitor process performance and maintain improvements.
• Use statistical process control tools to detect any deviations from desired performance.
• Document the improved process and provide training to ensure adherence.

By following the DMAIC model, manufacturing managers can systematically improve their processes, reduce costs, and enhance quality. Each phase plays a critical role in ensuring the success of a Lean Six Sigma project. For a detailed breakdown of the steps involved in each phase, refer to our comprehensive DMAIC process steps and integrate these with the DMAIC roadmap for manufacturing to ensure a structured approach to your projects. Use the DMAIC checklist for manufacturing projects to stay on track and review dmaic project examples in manufacturing for practical insights. For a deeper understanding of implementing these strategies, explore DMAIC implementation in the manufacturing industry .

Digitize your manufacturing process 10x faster at one-tenth the cost

A Real-World DMAIC Case Study

In the competitive arena of manufacturing, Lean Six Sigma methodologies have become vital for companies aiming to enhance their processes and output quality. This section will illustrate how the DMAIC model, a cornerstone of Lean Six Sigma, is applied in a real-world scenario to achieve these goals.

Background of the Case Study

This case study encompasses a mid-sized manufacturing firm facing challenges with product defects leading to customer dissatisfaction and increased waste. The company chose to employ the DMAIC model to systematize their process improvement efforts and reduce the defect rate in one of their key product lines.

Application of the Define Phase

In the Define phase, the project team established the project’s scope and objectives. They pinpointed the critical issue as an unacceptable level of product defects, which was established as a priority to address. The goal was set to reduce the defect rate by 50% within six months.

Execution of the Measure Phase

During the Measure phase, the team collected data on the current defect rate and identified the processes contributing to the defects. This data was crucial in establishing a baseline measure for improvement.

Insights from the Analyze Phase

The Analyze phase involved drilling down into the collected data to ascertain the root causes of defects. Using tools like fishbone diagrams and Pareto charts, the team determined that the majority of defects were originating in the assembly process due to outdated equipment and lack of skilled operators.

Solutions from the Improve Phase

In the Improve phase, the team implemented targeted solutions, including upgrading equipment and intensifying employee training programs. To support these improvements, they referred to the dmaic checklist for manufacturing projects .

Results from the Control Phase

The Control phase focused on maintaining the gains achieved. The team established ongoing monitoring procedures and KPIs to ensure that the improvements were sustained. Six months post-implementation, the defect rate had reduced by 55%, surpassing the initial goal.

The successful application of the DMAIC model in this real-world scenario underscores its effectiveness in manufacturing settings. Manufacturing managers can glean insights from this dmaic case study in manufacturing and consider how the dmaic roadmap for manufacturing can be tailored to their unique challenges. Continuous improvement is a journey, and the DMAIC model provides a structured path toward operational excellence. For further examples of DMAIC in action, explore dmaic project examples in manufacturing and consider the broader implications of dmaic implementation in the manufacturing industry .

Best Practices for Implementing DMAIC

Successfully implementing the DMAIC model in manufacturing demands a strategic approach. By adhering to best practices, manufacturing managers can ensure that process improvements are effectively realized and sustained over time. Here are the essential practices to consider during a DMAIC initiative.

Establishing a Project Team

A cross-functional team is critical to the success of a DMAIC project. It’s vital to gather a group with diverse expertise and knowledge of the process under scrutiny. Team members should include process owners, front-line employees, and data analysts, ensuring a comprehensive understanding of the issues at hand.

By assembling a capable team, organizations can foster collaborative problem-solving and leverage a range of perspectives. Further information on forming effective project teams can be found in our article on dmaic process steps .

Ensuring Accurate Data Collection

Data is the backbone of any DMAIC project. Accurate data collection is imperative for identifying true root causes and measuring the impact of implemented solutions. It’s essential to establish clear data collection methods and ensure that all data sources are reliable.

Manufacturing managers should train their teams on proper data collection techniques and reinforce the importance of accuracy. This includes defining data points, specifying measurement intervals, and standardizing data recording procedures. For a comprehensive list of best practices in data collection, see our dmaic checklist for manufacturing projects .

Utilizing Digital Tools for Process Digitization

The adoption of digital tools can significantly enhance the efficiency of the DMAIC process. Software solutions for process mapping, statistical analysis, and real-time monitoring can streamline data collection and analysis, allowing for quicker and more accurate decision-making.

Digital tools facilitate the storage and sharing of project documentation, ensuring that all team members have access to the latest information. They also support the tracking of project progress and KPIs, which are crucial for achieving the desired outcomes. For examples of digital tool applications, refer to our article on dmaic project examples in manufacturing .

Engaging Stakeholders Throughout the Process

Stakeholder engagement is paramount throughout the DMAIC process. Keeping stakeholders informed and involved ensures their support and helps to align the project with the organization’s strategic objectives.

Communication with stakeholders should be frequent and transparent, providing updates on project status, milestones achieved, and any adjustments to the project scope. Encouraging feedback and suggestions from stakeholders can also provide valuable insights and foster a culture of continuous improvement. Discover strategies for stakeholder engagement in our guide to dmaic implementation in manufacturing industry .

By following these best practices, manufacturing managers can maximize the effectiveness of their DMAIC projects. Establishing a well-rounded project team, ensuring the accuracy of data collection, leveraging digital tools, and maintaining stakeholder engagement are all crucial steps in the journey towards process excellence. For a detailed guide on the DMAIC model, visit our dmaic roadmap for manufacturing .

Measuring Success in DMAIC Initiatives

Evaluating the effectiveness of Lean Six Sigma projects is crucial to understanding their impact on manufacturing operations. Key Performance Indicators (KPIs), the long-term impact on operations, and the commitment to continuous improvement are the metrics that define the success of DMAIC initiatives.

Key Performance Indicators (KPIs) to Track

Tracking the right KPIs is essential for quantifying the success of a DMAIC project. These indicators should align with the initial goals set during the Define phase and can include metrics such as:

Manufacturing managers can refer to the dmaic checklist for manufacturing projects to ensure they are monitoring the appropriate metrics.

Long-Term Impact on Manufacturing Operations

The long-term impact of DMAIC initiatives extends beyond the immediate improvements. Successful implementation can lead to:

• Enhanced Quality : Consistent production of higher-quality products.
• Increased Productivity : More efficient use of resources and time.
• Cost Reduction : Sustainable savings through waste elimination and process optimization.
• Higher Customer Satisfaction : Improved product quality and reliability leading to better customer retention.

For a deeper understanding of these long-term benefits, manufacturing managers can explore dmaic implementation in manufacturing industry .

Continuous Improvement Post DMAIC

DMAIC is not a one-time event but part of a culture of continuous improvement. After the Control phase, it is vital to:

• Monitor ongoing performance using the established KPIs.
• Regularly review processes to identify further areas for enhancement.
• Foster an environment where employees are encouraged to suggest improvements.

Following the DMAIC roadmap, as outlined in dmaic roadmap for manufacturing , ensures that continuous improvement becomes an integral part of operations.

Measuring the success of DMAIC initiatives involves a combination of tracking immediate improvements and assessing long-term effects on the manufacturing process. By embedding a culture of continuous improvement and leveraging KPIs, manufacturers can sustain the gains achieved through Lean Six Sigma projects. For more insights and real-world applications, managers can review dmaic project examples in manufacturing to see how other organizations have achieved success with DMAIC.

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Case Study | Project Management for Industrial Manufacturer

Industrial Manufacturer

Industrial Manufacturing

CONSULTANT ROLE

Project Manager

The Challenge

Refine Project Management Workflows

The client, a leading German industrial manufacturer, sought a project manager to refine the workflows of the Lifecycle Management Platform.

Role of Consultport

Consultport proposed 2 candidates within 24 hours. The client interviewed both candidates and selected a former consultant at Roland Berger with a specialization in PMO consulting and prior experiences working in several large German manufacturing companies. The project manager started working with the client 48 hours after the initial request.

Well-rounded Assessment

The project manager conducted process analysis to assess existing practices for project planning, resource allocation and risk assessment. He also performed stakeholder mapping to gain insights into roles and expectations of key stakeholders. Through the assessment, the project manager identified gaps in the current project management practices.

Improving Project Management Structure

The project manager proposed a refined project management structure with distinct workflows, clearly outlining goals and responsibilities for global and regional teams. Responsible for leading four agile teams, the project manager ensured regular exchange between business and IT teams to align priorities and tasks. 

The project manager also developed clear guidelines for selecting project steering committees and designed standardized communication practices to enable efficient collaboration between key stakeholders. In addition, internal workshops were held to educate team members on the new project management practices.

Optimized Project Management

With the refined project management practices, the client enjoyed streamlined workflows, improved resource allocation and enhanced stakeholder engagement, resulting in on-time project delivery.

Refined Project Management Structure

Enhanced Stakeholder Engagement

On-time Project Delivery

It was a pleasure collaborating with the project manager. His project management approach was invaluable in meeting our project goals and timelines.

Head of Digital Platforms of Industrial Manufacturer

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Operational Excellence in Manufacturing Case Study Example: Johnson Controls

We are proud to offer our BTOES Insights community with access to the very best Award-Winning Examples of Successful Operational Excellence from the Business Transformation & Operational Excellence Awards, 2017. You can learn more about the awards here .  Click below for access to our Award-Winning entry for Best Achievement of Operational Excellence in Manufacturing from Johnson Controls.

The Operational Excellence Manufacturing Project Johnson Controls launched a Manufacturing Excellence Strategy in 2013 to achieve its vision of becoming the most operationally capable company in the world. The centerpiece of the strategy, which was developed by a global cross business unit team, is the Johnson Controls Manufacturing System (JCMS).

The system has four foundations:

• Customer focus
• Stable production environment
• Zero tolerance for waste
• Organize around pull

Alongside this, The Johnson Controls Manufacturing System bears nine principles that provide a comprehensive model with clear roadmaps for engaging employees, driving manufacturing excellence and growing the business via One Johnson Controls Way of manufacturing.

The Strategy for Achieving Operational Excellence

Enabling dimensions of the strategy to achieve Operational Excellence in their manufacturing plants include: an Operations Academy; a web application for assessing a baseline, establishing action plans and real-time reporting of progress; high performance teams that empower the shop floor and hold it accountable for improvement; regional subject matter experts in the nine principles; business partners that plant managers can tap for coaching/assistance; an enterprise support team; and an incentive structure.

JCMS was introduced to all business unit operations leaders responsible for the company’s more than 300 plants around the globe in September 2014. After initial deployment, the company piloted an Operational Excellence acceleration phase in 2015 that focused on building manufacturing capabilities, implementing quick wins and removing waste in one model line to demonstrate results and to drive adoption of JCMS, leading by example.

The plants that have made the greatest progress adopting JCMS have set a great example of Operational Excellence achieved in manufacturing, having demonstrated significant improvements in safety, quality, productivity, and delivery, resulting in greater customer satisfaction and employee engagement.

All the best,

Charlotte Kelly Editor BTOES Insights

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9 Real-Life Lean Manufacturing Examples

Lean manufacturing allows companies to better optimize processes, reduce waste, and speed up production times through different methods, tools, and philosophies. If you're wondering how to implement lean manufacturing techniques in your operations, you need to consider which lean production tools you use and what you want to accomplish.

How Does Lean Manufacturing Work?

Lean manufacturing is a systematic approach to improving efficiency and reducing waste in manufacturing processes. It focuses on creating more value for customers while using fewer resources. This is achieved by identifying and eliminating all types of waste, including defects, overproduction, waiting, unnecessary motion, excess inventory, overprocessing, and unused talent. Lean manufacturing also emphasizes continuous improvement, involving all employees in the process of identifying and solving problems. By applying lean principles, companies can reduce lead times, improve quality, increase productivity, and lower costs.

Why Is Lean Manufacturing Important and How Can It Help?

Lean manufacturing is important because it helps companies stay competitive in today's fast-paced and ever-changing business environment. By improving efficiency and reducing waste, companies can offer better products and services at lower costs, which can attract and retain customers. Lean manufacturing can also help companies reduce their environmental impact by minimizing resource consumption and waste generation. Moreover, lean manufacturing can improve employee morale and engagement by empowering them to participate in continuous improvement activities and take ownership of their work. Overall, lean manufacturing can help companies achieve long-term success by creating value for customers, employees, and stakeholders.

Getting Started with Lean Manufacturing Methods

A great way to start considering methods is by exploring real-life examples of lean manufacturing and lean management. This can provide a deeper level of understanding and help you build up the confidence to implement the same lean thinking philosophies. We've compiled a list of nine examples for you to start with.

9 Lean Manufacturing Examples in the Real World

Kaizen is a Japanese term that means "continuous improvement." In the context of lean manufacturing, it refers to the idea of involving all employees in identifying and implementing small, incremental improvements in processes, products, or services. Kaizen encourages continuous learning and innovation , as well as a sense of ownership and engagement among employees.  Some examples of kaizen activities include participating in quality circles, conducting 5S audits, or attending training sessions to learn new skills or techniques.

2. Just-in-time

Just-in-time (JIT) is a manufacturing philosophy that aims to produce only what is needed, when it is needed, and in the exact quantity needed. JIT helps companies minimize inventory and reduce waste, while also improving efficiency and responsiveness to customer demand. Some examples of JIT in action include using pull production systems, where production is triggered by customer orders rather than a forecast, or establishing close relationships with suppliers to ensure the timely delivery of materials.

Kanban is a visual tool that helps companies manage inventory and production by signaling when it is time to replenish supplies or move materials to the next stage of production.  Kanban can take many forms, such as colored cards, electronic displays, or physical containers. By using kanban, companies can improve communication and coordination between different departments or functions, as well as reduce lead times and minimize waste.

4. Standardization

Standardization refers to the process of creating and implementing standard operating procedures (SOPs) for a given process or task. SOPs help ensure consistency and quality in products or services, as well as reduce variability and errors. Standardized work instructions can include visual aids, such as diagrams and photos, to help workers understand the process, and they can be updated as improvements are made. For example, standardization can be applied to the layout and design of the factory floor. The location of tools and equipment can be standardized so that workers can quickly find what they need, reducing wasted time and motion. The use of color-coded labels and markings can also help ensure that workers can quickly identify different parts and materials, reducing the risk of errors and accidents.

5. Value stream mapping

Value stream mapping is a tool used to visualize and analyze the flow of materials, information, and activities required to deliver a product or service to a customer. Value stream mapping helps companies identify and eliminate waste, as well as optimize the entire value stream from end to end. Value stream mapping can also reveal opportunities for improvement and innovation, such as reducing lead times, improving quality, or increasing flexibility.

6. Pull production

Pull production is a manufacturing approach where production is triggered by customer demand, rather than a forecast or a push from upstream processes. Pull production helps companies reduce inventory, improve responsiveness to customer demand, and minimize waste. Pull production can take many forms, such as kanban systems, supermarkets, or direct customer orders.

5S is a workplace organization and cleanliness system that helps companies improve safety, efficiency, and quality. The five S's stand for Sort, Straighten, Sweep, Standardize, and Sustain.

Sort refers to the process of separating necessary items from unnecessary ones and disposing of the latter. Straighten refers to the process of organizing the workplace and arranging items in a logical and efficient manner. Sweep refers to the process of cleaning and maintaining the workplace to ensure safety and hygiene. Standardize refers to the process of establishing and maintaining standards for workplace organization and cleanliness. Sustain refers to the process of continuously improving and refining the 5S system.

One of the most powerful lean manufacturing tools available to manufacturers is the SMED event . In a nutshell, SMED events enable manufacturers to identify—and remove—the waste in their changeover processes. All manufacturers, regardless of size, can benefit from SMED. Typically, SMED events reduce changeover times by 30-50%!

Steps include mapping your current changeover process; analyzing, extracting, and streamlining steps; and documenting the whole process to present to your organization.

9. Continuous flow

Continuous flow is a manufacturing approach that aims to produce products in a continuous and uninterrupted flow, rather than in batches. This approach helps companies minimize inventory, reduce lead times, and improve efficiency by eliminating waiting times and reducing the need for transportation and handling. Continuous flow is often used in industries such as food processing, pharmaceuticals, and electronics, where high levels of quality and consistency are required, and where the cost of errors or defects is high.  Some examples of continuous flow in action include assembly line production, where each worker performs a specific task in a sequential manner, or cellular manufacturing, where groups of machines and workers are organized in a flow line to produce a family of related products.

Major Companies That Exemplify Lean Management Practices

You can’t talk about lean manufacturing without talking about Toyota. This Japanese auto manufacturer is credited with the birth of the Toyota Production System (TPS) . Created by Sakichi Toyoda, the goal of TPS was to eliminate waste from the manufacturing process. Nowadays, TPS is known as a fundamental lean manufacturing methodology. But Toyota didn’t stop at TPS. They also used a methodology called jidoka to minimize faulty products, and kaizen to pursue continuous improvement. They focused on automating several processes to lower human error and recheck product quality. Then, they implemented the just-in-time (JIT) model, so that they would only begin working on a product when there was a demand for it. This helped them to better control inventory levels and prevented overproduction.

FedEx Express

In response to the 2008 recession, FedEx began implementing lean manufacturing strategies to reduce costs. One of the ways they changed their operations was by introducing milestones in their C-check process for aircraft maintenance. The team identified 68 milestones crucial to the C-check and defined each segment in 4-hour increments.  Identifying milestones enabled a smoother workflow, which greatly reduced wasted time. The FedEx Express crew at LAX went from performing 14 C-checks a year to performing 30 a year. The crew also went from needing 32,715 man-hours for a C-check to 21,535 (and decreasing). Eliminating wasted time like this leads to huge cost savings, especially in an industry like aircraft maintenance, where specialized mechanics and technicians are quite costly.

With almost 800 contracted factories involved in their manufacturing processes, it’s no surprise that Nike places a heavy emphasis on consistency and waste reduction. To do so, Nike adopted continuous improvement practices and developed the Manufacturing Index in 2011: a framework with key benchmarks and performance indicators to reduce miscommunications, waste, and inconsistency across manufacturers.  The index contains lean elements like “just-in-time” and a continuous improvement mindset. Just-in-time (JIT) production is a simple inventory system where you only produce if there is a demand for your production. This is the pillar of the TPS principles. By not having excess inventory lying around, you reduce waste and save space.

Harley-Davidson

Harley-Davidson  used Total Productive Maintenance (TPM) along with the 5S system and Standard Work as the main foundations of their strategy to keep their techniques stable. Then, they added other lean tools—such as kaizen and Six Sigma—to help improve operations and problem-solve issues. The company also adopted just-in-time inventory management and value stream mapping. The result? Having exactly the right inventory levels at the right times, avoiding waste and providing value to their customers. With these tools, Harley-Davidson automated processes to increase productivity, improve lead times, and reduce their transportation expenses.

John Deere Production System

John Deere started their lean thinking with production processes before moving on to improving their logistics and their supply chain. For John Deere, adopting continuous improvement processes took the form of automated quality control mechanisms. These mechanisms could check more products in less time, allowing for workers to spot defects — and subsequently fix them — more quickly. They were also able to get more products out the door and into customers' hands.

Kimberly-Clark

Kimberly-Clark felt that they were overspending on their transportation management system (TMS). Kimberly-Clark sought continuous improvement to further automate the system, which freed up more time for analysts to perform proactive work that benefited the company. The automation also allowed them to perform more processes with less clicks and fewer steps within the application.

Intel’s components have to be produced with the highest quality—and meet extremely high customer demand. With such demand, Intel could have lowered their cycle time to increase output, but that would have resulted in poorer quality and increased the chance of product defects. Instead, the semiconductor company turned to lean techniques to reduce works-in-process (WIP) and get rid of process waste without hindering workflow. Then, they implemented quality control methods. These lean tools helped to boost productivity without sacrificing quality for their products.

The Ford Motor Company has always aimed to produce the highest quality products and innovations in the industry. Knowing that its operational strength lay in its assembly line, Ford adopted kaizen, lean manufacturing methodologies , Six Sigma, and Total Quality Management (TQM) to implement the concept of continuous improvement in their processes.  Adopting automation and standardization allowed the company to create production lines that flowed efficiently as products moved through each workstation. Using these methods, Ford improved product quality, reduced costs, and decreased waste.

Bank of America

Bank of America is one of many financial institutions that apply a hybrid of lean manufacturing principles and Six Sigma to their operations. Before employing these principles, the organization was experiencing low customer satisfaction rates due to their process quality. They had many issues with customers' statements including encoding errors, late posting transactions, and omissions.  With lean Six Sigma, they improved operational efficiency while meeting the customer needs. They also managed to continuously assess performance using the right performance data metrics to ensure optimized processes.

General Electric

General Electric (GE) recently took on lean management t with the arrival of their new CEO and chairman in 2018. When the company first adopted lean techniques in their project management operations, their innovations actually created bottlenecks in other processes. This led to too much downtime and inventory, which in turn created more waste.  To correct this, GE’s management team turned to Genba. Genba is a lean manufacturing too l used to evaluate the processes on the work floor and learn more about the issues. They sent work operators and support team members to obtain lean training, then performed value stream mapping to identify process value and potential areas of waste. After changing tactics, they were able to correct their first pass at employing lean strategies.

Improve Your Factory with Lean Manufacturing Tools Like Amper

Implementing lean manufacturing principles and lean tools often requires the help of software. Trying to manually track, monitor, and organize the different steps of a lean process is overwhelming and can easily lead to errors and slowdowns. However, with the help of technology like production monitoring, machine monitoring, and IoT and cloud computing, you can track the waste and value in all of your manufacturing systems and develop better ways to reduce waste and increase profitability.

You can apply lean manufacturing to your operations in a vast number of ways. The nine case studies above show that with the right lean tools and techniques, it’s possible to overhaul systems, equipment, production lines, and worker output to continually improve operations. These are just a few success stories  within their industries that can inspire other manufacturers to pursue similar tactics. Here at Amper, we offer OEE and machine monitoring to further automate and enhance lean manufacturing system strategies that you adopt within your operations. Contact us to learn more about our tools and resources, or schedule a demo today!

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Additive manufacturing case studies

A collection of case studies aimed to inform you of how additive manufacturing can impact your business, the latest developments in the technology and the applications where we see the technology applied.

Featured case study

Material innovation through metal additive manufacturing: a case study with uniform wares and betatype.

Watchmaker Uniform Wares partnered with Betatype to explore the advantages of additive manufacturing (AM) technology, pushing the boundaries of design in an industry traditionally centred around heritage. As a result, they produced a superior quality, mesh 3D printed titanium watch strap.

Choose an industry to discover more

Learn more about how AM can be used in aerospace applications.

Learn more about how AM can be used in automotive applications.

Learn more about how AM can be used in medical and healthcare applications.

Learn more about how AM can be used in heavy industry applications.

Learn more about how AM can be used in precision manufacturing applications.

Learn more about how AM can be used in energy applications.

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Lean Six Sigma Project Examples | 17 Full Case Studies

Ready to begin your first Lean Six Sigma project? Looking for examples for inspiration or reference to get you started? Here are some project storyboards from different industries and from home. Remember, Lean Six Sigma can help you with more than just work!

• Reducing Underwriting Resubmits by Over 20%  

Governments

• A Call to Change: Pioneering Lean Six Sigma at Los Angeles County  
• Can Lean Six Sigma Be Applied in County Government?  
• How the City of San Antonio Increased Payments for Street Maintenance Using Lean Six Sigma  
• Reducing Bid Tab Creation Cycle Time by 22%  
• Reducing Cycle Time for Natural Disaster Response by 50%  

Manufacturing

• Increasing First Run Parts From 60% to 90% With Lean Six Sigma  
• Reducing Bent/Scratched/Damaged (BSD) Scrap for Building Envelopes  
• Reducing Lead Time in Customer Replacement Part Orders by 41%  
• Reducing Learning Curve Ramp for Temp Employees by 2 Weeks  
• Reducing Purchase Order Lead Time by 33% Using Lean Six Sigma  
• Herding Cats Using Lean Six Sigma: How to Plan for and Manage the Chaos of Parallel Processes  
• Lean Six Sigma Increases Daily Meat Production by 25%  
• Lean Six Sigma Helps Feed People In Need 45% Faster  
• Accelerating Lean Productivity With Immersive Collaboration  
• Reducing Incorrect Router Installations by 60% for Call One  
• Reducing Software Bug Fix Lead Time From 25 to 15 Days  

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15 Real-Life Case Study Examples & Best Practices

Written by: Oghale Olori

Case studies are more than just success stories.

They are powerful tools that demonstrate the practical value of your product or service. Case studies help attract attention to your products, build trust with potential customers and ultimately drive sales.

It’s no wonder that 73% of successful content marketers utilize case studies as part of their content strategy. Plus, buyers spend 54% of their time reviewing case studies before they make a buying decision.

To ensure you’re making the most of your case studies, we’ve put together 15 real-life case study examples to inspire you. These examples span a variety of industries and formats. We’ve also included best practices, design tips and templates to inspire you.

Let’s dive in!

Table of Contents

What is a case study, 15 real-life case study examples, sales case study examples, saas case study examples, product case study examples, marketing case study examples, business case study examples, case study faqs.

• A case study is a compelling narrative that showcases how your product or service has positively impacted a real business or individual. 
• Case studies delve into your customer's challenges, how your solution addressed them and the quantifiable results they achieved.
• Your case study should have an attention-grabbing headline, great visuals and a relevant call to action. Other key elements include an introduction, problems and result section.
• Visme provides easy-to-use tools, professionally designed templates and features for creating attractive and engaging case studies.

A case study is a real-life scenario where your company helped a person or business solve their unique challenges. It provides a detailed analysis of the positive outcomes achieved as a result of implementing your solution.

Case studies are an effective way to showcase the value of your product or service to potential customers without overt selling. By sharing how your company transformed a business, you can attract customers seeking similar solutions and results.

Case studies are not only about your company's capabilities; they are primarily about the benefits customers and clients have experienced from using your product.

Every great case study is made up of key elements. They are;

• Attention-grabbing headline: Write a compelling headline that grabs attention and tells your reader what the case study is about. For example, "How a CRM System Helped a B2B Company Increase Revenue by 225%.
• Introduction/Executive Summary: Include a brief overview of your case study, including your customer’s problem, the solution they implemented and the results they achieved.
• Problem/Challenge: Case studies with solutions offer a powerful way to connect with potential customers. In this section, explain how your product or service specifically addressed your customer's challenges.
• Solution: Explain how your product or service specifically addressed your customer's challenges.
• Results/Achievements : Give a detailed account of the positive impact of your product. Quantify the benefits achieved using metrics such as increased sales, improved efficiency, reduced costs or enhanced customer satisfaction.
• Graphics/Visuals: Include professional designs, high-quality photos and videos to make your case study more engaging and visually appealing.
• Quotes/Testimonials: Incorporate written or video quotes from your clients to boost your credibility.
• Relevant CTA: Insert a call to action (CTA) that encourages the reader to take action. For example, visiting your website or contacting you for more information. Your CTA can be a link to a landing page, a contact form or your social media handle and should be related to the product or service you highlighted in your case study.

Now that you understand what a case study is, let’s look at real-life case study examples. Among these, you'll find some simple case study examples that break down complex ideas into easily understandable solutions.

In this section, we’ll explore SaaS, marketing, sales, product and business case study examples with solutions. Take note of how these companies structured their case studies and included the key elements.

We’ve also included professionally designed case study templates to inspire you.

1. Georgia Tech Athletics Increase Season Ticket Sales by 80%

Georgia Tech Athletics, with its 8,000 football season ticket holders, sought for a way to increase efficiency and customer engagement.

Their initial sales process involved making multiple outbound phone calls per day with no real targeting or guidelines. Georgia Tech believed that targeting communications will enable them to reach more people in real time.

Salesloft improved Georgia Tech’s sales process with an inbound structure. This enabled sales reps to connect with their customers on a more targeted level. The use of dynamic fields and filters when importing lists ensured prospects received the right information, while communication with existing fans became faster with automation.

As a result, Georgia Tech Athletics recorded an 80% increase in season ticket sales as relationships with season ticket holders significantly improved. Employee engagement increased as employees became more energized to connect and communicate with fans.

Why Does This Case Study Work?

In this case study example , Salesloft utilized the key elements of a good case study. Their introduction gave an overview of their customers' challenges and the results they enjoyed after using them. After which they categorized the case study into three main sections: challenge, solution and result.

Salesloft utilized a case study video to increase engagement and invoke human connection.

Incorporating videos in your case study has a lot of benefits. Wyzol’s 2023 state of video marketing report showed a direct correlation between videos and an 87% increase in sales.

The beautiful thing is that creating videos for your case study doesn’t have to be daunting.

With an easy-to-use platform like Visme, you can create top-notch testimonial videos that will connect with your audience. Within the Visme editor, you can access over 1 million stock photos , video templates, animated graphics and more. These tools and resources will significantly improve the design and engagement of your case study.

Simplify content creation and brand management for your team

• Collaborate on designs , mockups and wireframes with your non-design colleagues
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2. WeightWatchers Completely Revamped their Enterprise Sales Process with HubSpot

WeightWatchers, a 60-year-old wellness company, sought a CRM solution that increased the efficiency of their sales process. With their previous system, Weightwatchers had limited automation. They would copy-paste message templates from word documents or recreate one email for a batch of customers.

This required a huge effort from sales reps, account managers and leadership, as they were unable to track leads or pull customized reports for planning and growth.

WeightWatchers transformed their B2B sales strategy by leveraging HubSpot's robust marketing and sales workflows. They utilized HubSpot’s deal pipeline and automation features to streamline lead qualification. And the customized dashboard gave leadership valuable insights.

As a result, WeightWatchers generated seven figures in annual contract value and boosted recurring revenue. Hubspot’s impact resulted in 100% adoption across all sales, marketing, client success and operations teams.

Hubspot structured its case study into separate sections, demonstrating the specific benefits of their products to various aspects of the customer's business. Additionally, they integrated direct customer quotes in each section to boost credibility, resulting in a more compelling case study.

Getting insight from your customer about their challenges is one thing. But writing about their process and achievements in a concise and relatable way is another. If you find yourself constantly experiencing writer’s block, Visme’s AI writer is perfect for you.

Visme created this AI text generator tool to take your ideas and transform them into a great draft. So whether you need help writing your first draft or editing your final case study, Visme is ready for you.

3. Immi’s Ram Fam Helps to Drive Over $200k in Sales

Immi embarked on a mission to recreate healthier ramen recipes that were nutritious and delicious. After 2 years of tireless trials, Immi finally found the perfect ramen recipe. However, they envisioned a community of passionate ramen enthusiasts to fuel their business growth.

This vision propelled them to partner with Shopify Collabs. Shopify Collabs successfully cultivated and managed Immi’s Ramen community of ambassadors and creators.

As a result of their partnership, Immi’s community grew to more than 400 dedicated members, generating over $200,000 in total affiliate sales.

The power of data-driven headlines cannot be overemphasized. Chili Piper strategically incorporates quantifiable results in their headlines. This instantly sparks curiosity and interest in readers.

While not every customer success story may boast headline-grabbing figures, quantifying achievements in percentages is still effective. For example, you can highlight a 50% revenue increase with the implementation of your product.

Take a look at the beautiful case study template below. Just like in the example above, the figures in the headline instantly grab attention and entice your reader to click through.

Having a case study document is a key factor in boosting engagement. This makes it easy to promote your case study in multiple ways. With Visme, you can easily publish, download and share your case study with your customers in a variety of formats, including PDF, PPTX, JPG and more!

4. How WOW! is Saving Nearly 79% in Time and Cost With Visme

This case study discusses how Visme helped WOW! save time and money by providing user-friendly tools to create interactive and quality training materials for their employees. Find out what your team can do with Visme. Request a Demo

WOW!'s learning and development team creates high-quality training materials for new and existing employees. Previous tools and platforms they used had plain templates, little to no interactivity features, and limited flexibility—that is, until they discovered Visme.

Now, the learning and development team at WOW! use Visme to create engaging infographics, training videos, slide decks and other training materials.

This has directly reduced the company's turnover rate, saving them money spent on recruiting and training new employees. It has also saved them a significant amount of time, which they can now allocate to other important tasks.

Visme's customer testimonials spark an emotional connection with the reader, leaving a profound impact. Upon reading this case study, prospective customers will be blown away by the remarkable efficiency achieved by Visme's clients after switching from PowerPoint.

Visme’s interactivity feature was a game changer for WOW! and one of the primary reasons they chose Visme.

“Previously we were using PowerPoint, which is fine, but the interactivity you can get with Visme is so much more robust that we’ve all steered away from PowerPoint.” - Kendra, L&D team, Wow!

Visme’s interactive feature allowed them to animate their infographics, include clickable links on their PowerPoint designs and even embed polls and quizzes their employees could interact with.

By embedding the slide decks, infographics and other training materials WOW! created with Visme, potential customers get a taste of what they can create with the tool. This is much more effective than describing the features of Visme because it allows potential customers to see the tool in action.

To top it all off, this case study utilized relevant data and figures. For example, one part of the case study said, “In Visme, where Kendra’s team has access to hundreds of templates, a brand kit, and millions of design assets at their disposal, their team can create presentations in 80% less time.”

Who wouldn't want that?

Including relevant figures and graphics in your case study is a sure way to convince your potential customers why you’re a great fit for their brand. The case study template below is a great example of integrating relevant figures and data.

This colorful template begins with a captivating headline. But that is not the best part; this template extensively showcases the results their customer had using relevant figures.

The arrangement of the results makes it fun and attractive. Instead of just putting figures in a plain table, you can find interesting shapes in your Visme editor to take your case study to the next level.

5. Lyte Reduces Customer Churn To Just 3% With Hubspot CRM

While Lyte was redefining the ticketing industry, it had no definite CRM system . Lyte utilized 12–15 different SaaS solutions across various departments, which led to a lack of alignment between teams, duplication of work and overlapping tasks.

Customer data was spread across these platforms, making it difficult to effectively track their customer journey. As a result, their churn rate increased along with customer dissatisfaction.

Through Fuelius , Lyte founded and implemented Hubspot CRM. Lyte's productivity skyrocketed after incorporating Hubspot's all-in-one CRM tool. With improved efficiency, better teamwork and stronger client relationships, sales figures soared.

The case study title page and executive summary act as compelling entry points for both existing and potential customers. This overview provides a clear understanding of the case study and also strategically incorporates key details like the client's industry, location and relevant background information.

Having a good summary of your case study can prompt your readers to engage further. You can achieve this with a simple but effective case study one-pager that highlights your customer’s problems, process and achievements, just like this case study did in the beginning.

Moreover, you can easily distribute your case study one-pager and use it as a lead magnet to draw prospective customers to your company.

Take a look at this case study one-pager template below.

This template includes key aspects of your case study, such as the introduction, key findings, conclusion and more, without overcrowding the page. The use of multiple shades of blue gives it a clean and dynamic layout.

Our favorite part of this template is where the age group is visualized.

With Visme’s data visualization tool , you can present your data in tables, graphs, progress bars, maps and so much more. All you need to do is choose your preferred data visualization widget, input or import your data and click enter!

6. How Workato Converts 75% of Their Qualified Leads

Workato wanted to improve their inbound leads and increase their conversion rate, which ranged from 40-55%.

At first, Workato searched for a simple scheduling tool. They soon discovered that they needed a tool that provided advanced routing capabilities based on zip code and other criteria. Luckily, they found and implemented Chili Piper.

As a result of implementing Chili Piper, Workato achieved a remarkable 75–80% conversion rate and improved show rates. This led to a substantial revenue boost, with a 10-15% increase in revenue attributed to Chili Piper's impact on lead conversion.

This case study example utilizes the power of video testimonials to drive the impact of their product.

Chili Piper incorporates screenshots and clips of their tool in use. This is a great strategy because it helps your viewers become familiar with how your product works, making onboarding new customers much easier.

In this case study example, we see the importance of efficient Workflow Management Systems (WMS). Without a WMS, you manually assign tasks to your team members and engage in multiple emails for regular updates on progress.

However, when crafting and designing your case study, you should prioritize having a good WMS.

Visme has an outstanding Workflow Management System feature that keeps you on top of all your projects and designs. This feature makes it much easier to assign roles, ensure accuracy across documents, and track progress and deadlines.

Visme’s WMS feature allows you to limit access to your entire document by assigning specific slides or pages to individual members of your team. At the end of the day, your team members are not overwhelmed or distracted by the whole document but can focus on their tasks.

7. Rush Order Helps Vogmask Scale-Up During a Pandemic

Vomask's reliance on third-party fulfillment companies became a challenge as demand for their masks grew. Seeking a reliable fulfillment partner, they found Rush Order and entrusted them with their entire inventory.

Vomask's partnership with Rush Order proved to be a lifesaver during the COVID-19 pandemic. Rush Order's agility, efficiency and commitment to customer satisfaction helped Vogmask navigate the unprecedented demand and maintain its reputation for quality and service.

Rush Order’s comprehensive support enabled Vogmask to scale up its order processing by a staggering 900% while maintaining a remarkable customer satisfaction rate of 92%.

Rush Order chose one event where their impact mattered the most to their customer and shared that story.

While pandemics don't happen every day, you can look through your customer’s journey and highlight a specific time or scenario where your product or service saved their business.

The story of Vogmask and Rush Order is compelling, but it simply is not enough. The case study format and design attract readers' attention and make them want to know more. Rush Order uses consistent colors throughout the case study, starting with the logo, bold square blocks, pictures, and even headers.

Take a look at this product case study template below.

Just like our example, this case study template utilizes bold colors and large squares to attract and maintain the reader’s attention. It provides enough room for you to write about your customers' backgrounds/introductions, challenges, goals and results.

The right combination of shapes and colors adds a level of professionalism to this case study template.

8. AMR Hair & Beauty leverages B2B functionality to boost sales by 200%

With limits on website customization, slow page loading and multiple website crashes during peak events, it wasn't long before AMR Hair & Beauty began looking for a new e-commerce solution.

Their existing platform lacked effective search and filtering options, a seamless checkout process and the data analytics capabilities needed for informed decision-making. This led to a significant number of abandoned carts.

Upon switching to Shopify Plus, AMR immediately saw improvements in page loading speed and average session duration. They added better search and filtering options for their wholesale customers and customized their checkout process.

Due to this, AMR witnessed a 200% increase in sales and a 77% rise in B2B average order value. AMR Hair & Beauty is now poised for further expansion and growth.

This case study example showcases the power of a concise and impactful narrative.

To make their case analysis more effective, Shopify focused on the most relevant aspects of the customer's journey. While there may have been other challenges the customer faced, they only included those that directly related to their solutions.

Take a look at this case study template below. It is perfect if you want to create a concise but effective case study. Without including unnecessary details, you can outline the challenges, solutions and results your customers experienced from using your product.

Don’t forget to include a strong CTA within your case study. By incorporating a link, sidebar pop-up or an exit pop-up into your case study, you can prompt your readers and prospective clients to connect with you.

9. How a Marketing Agency Uses Visme to Create Engaging Content With Infographics

SmartBox Dental , a marketing agency specializing in dental practices, sought ways to make dental advice more interesting and easier to read. However, they lacked the design skills to do so effectively.

Visme's wide range of templates and features made it easy for the team to create high-quality content quickly and efficiently. SmartBox Dental enjoyed creating infographics in as little as 10-15 minutes, compared to one hour before Visme was implemented.

By leveraging Visme, SmartBox Dental successfully transformed dental content into a more enjoyable and informative experience for their clients' patients. Therefore enhancing its reputation as a marketing partner that goes the extra mile to deliver value to its clients.

Visme creatively incorporates testimonials In this case study example.

By showcasing infographics and designs created by their clients, they leverage the power of social proof in a visually compelling way. This way, potential customers gain immediate insight into the creative possibilities Visme offers as a design tool.

This example effectively showcases a product's versatility and impact, and we can learn a lot about writing a case study from it. Instead of focusing on one tool or feature per customer, Visme took a more comprehensive approach.

Within each section of their case study, Visme explained how a particular tool or feature played a key role in solving the customer's challenges.

For example, this case study highlighted Visme’s collaboration tool . With Visme’s tool, the SmartBox Dental content team fostered teamwork, accountability and effective supervision.

Visme also achieved a versatile case study by including relevant quotes to showcase each tool or feature. Take a look at some examples;

Visme’s collaboration tool: “We really like the collaboration tool. Being able to see what a co-worker is working on and borrow their ideas or collaborate on a project to make sure we get the best end result really helps us out.”

Visme’s library of stock photos and animated characters: “I really love the images and the look those give to an infographic. I also really like the animated little guys and the animated pictures. That’s added a lot of fun to our designs.”

Visme’s interactivity feature: “You can add URLs and phone number links directly into the infographic so they can just click and call or go to another page on the website and I really like adding those hyperlinks in.”

You can ask your customers to talk about the different products or features that helped them achieve their business success and draw quotes from each one.

10. Jasper Grows Blog Organic Sessions 810% and Blog-Attributed User Signups 400X

Jasper, an AI writing tool, lacked a scalable content strategy to drive organic traffic and user growth. They needed help creating content that converted visitors into users. Especially when a looming domain migration threatened organic traffic.

To address these challenges, Jasper partnered with Omniscient Digital. Their goal was to turn their content into a growth channel and drive organic growth. Omniscient Digital developed a full content strategy for Jasper AI, which included a content audit, competitive analysis, and keyword discovery.

Through their collaboration, Jasper’s organic blog sessions increased by 810%, despite the domain migration. They also witnessed a 400X increase in blog-attributed signups. And more importantly, the content program contributed to over $4 million in annual recurring revenue.

The combination of storytelling and video testimonials within the case study example makes this a real winner. But there’s a twist to it. Omniscient segmented the video testimonials and placed them in different sections of the case study.

Video marketing , especially in case studies, works wonders. Research shows us that 42% of people prefer video testimonials because they show real customers with real success stories. So if you haven't thought of it before, incorporate video testimonials into your case study.

Take a look at this stunning video testimonial template. With its simple design, you can input the picture, name and quote of your customer within your case study in a fun and engaging way.

Try it yourself! Customize this template with your customer’s testimonial and add it to your case study!

11. How Meliá Became One of the Most Influential Hotel Chains on Social Media

Meliá Hotels needed help managing their growing social media customer service needs. Despite having over 500 social accounts, they lacked a unified response protocol and detailed reporting. This largely hindered efficiency and brand consistency.

Meliá partnered with Hootsuite to build an in-house social customer care team. Implementing Hootsuite's tools enabled Meliá to decrease response times from 24 hours to 12.4 hours while also leveraging smart automation.

In addition to that, Meliá resolved over 133,000 conversations, booking 330 inquiries per week through Hootsuite Inbox. They significantly improved brand consistency, response time and customer satisfaction.

The need for a good case study design cannot be over-emphasized.

As soon as anyone lands on this case study example, they are mesmerized by a beautiful case study design. This alone raises the interest of readers and keeps them engaged till the end.

If you’re currently saying to yourself, “ I can write great case studies, but I don’t have the time or skill to turn it into a beautiful document.” Say no more.

Visme’s amazing AI document generator can take your text and transform it into a stunning and professional document in minutes! Not only do you save time, but you also get inspired by the design.

With Visme’s document generator, you can create PDFs, case study presentations , infographics and more!

Take a look at this case study template below. Just like our case study example, it captures readers' attention with its beautiful design. Its dynamic blend of colors and fonts helps to segment each element of the case study beautifully.

12. Tea’s Me Cafe: Tamika Catchings is Brewing Glory

Tamika's journey began when she purchased Tea's Me Cafe in 2017, saving it from closure. She recognized the potential of the cafe as a community hub and hosted regular events centered on social issues and youth empowerment.

One of Tamika’s business goals was to automate her business. She sought to streamline business processes across various aspects of her business. One of the ways she achieves this goal is through Constant Contact.

Constant Contact became an integral part of Tamika's marketing strategy. They provided an automated and centralized platform for managing email newsletters, event registrations, social media scheduling and more.

This allowed Tamika and her team to collaborate efficiently and focus on engaging with their audience. They effectively utilized features like WooCommerce integration, text-to-join and the survey builder to grow their email list, segment their audience and gather valuable feedback.

The case study example utilizes the power of storytelling to form a connection with readers. Constant Contact takes a humble approach in this case study. They spotlight their customers' efforts as the reason for their achievements and growth, establishing trust and credibility.

This case study is also visually appealing, filled with high-quality photos of their customer. While this is a great way to foster originality, it can prove challenging if your customer sends you blurry or low-quality photos.

If you find yourself in that dilemma, you can use Visme’s AI image edit tool to touch up your photos. With Visme’s AI tool, you can remove unwanted backgrounds, erase unwanted objects, unblur low-quality pictures and upscale any photo without losing the quality.

Constant Contact offers its readers various formats to engage with their case study. Including an audio podcast and PDF.

In its PDF version, Constant Contact utilized its brand colors to create a stunning case study design.  With this, they increase brand awareness and, in turn, brand recognition with anyone who comes across their case study.

With Visme’s brand wizard tool , you can seamlessly incorporate your brand assets into any design or document you create. By inputting your URL, Visme’s AI integration will take note of your brand colors, brand fonts and more and create branded templates for you automatically.

You don't need to worry about spending hours customizing templates to fit your brand anymore. You can focus on writing amazing case studies that promote your company.

13. How Breakwater Kitchens Achieved a 7% Growth in Sales With Thryv

Breakwater Kitchens struggled with managing their business operations efficiently. They spent a lot of time on manual tasks, such as scheduling appointments and managing client communication. This made it difficult for them to grow their business and provide the best possible service to their customers.

David, the owner, discovered Thryv. With Thryv, Breakwater Kitchens was able to automate many of their manual tasks. Additionally, Thryv integrated social media management. This enabled Breakwater Kitchens to deliver a consistent brand message, captivate its audience and foster online growth.

As a result, Breakwater Kitchens achieved increased efficiency, reduced missed appointments and a 7% growth in sales.

This case study example uses a concise format and strong verbs, which make it easy for readers to absorb the information.

At the top of the case study, Thryv immediately builds trust by presenting their customer's complete profile, including their name, company details and website. This allows potential customers to verify the case study's legitimacy, making them more likely to believe in Thryv's services.

However, manually copying and pasting customer information across multiple pages of your case study can be time-consuming.

To save time and effort, you can utilize Visme's dynamic field feature . Dynamic fields automatically insert reusable information into your designs.  So you don’t have to type it out multiple times.

14. Zoom’s Creative Team Saves Over 4,000 Hours With Brandfolder

Zoom experienced rapid growth with the advent of remote work and the rise of the COVID-19 pandemic. Such growth called for agility and resilience to scale through.

At the time, Zoom’s assets were disorganized which made retrieving brand information a burden. Zoom’s creative manager spent no less than 10 hours per week finding and retrieving brand assets for internal teams.

Zoom needed a more sustainable approach to organizing and retrieving brand information and came across Brandfolder. Brandfolder simplified and accelerated Zoom’s email localization and webpage development. It also enhanced the creation and storage of Zoom virtual backgrounds.

With Brandfolder, Zoom now saves 4,000+ hours every year. The company also centralized its assets in Brandfolder, which allowed 6,800+ employees and 20-30 vendors to quickly access them.

Brandfolder infused its case study with compelling data and backed it up with verifiable sources. This data-driven approach boosts credibility and increases the impact of their story.

Bradfolder's case study goes the extra mile by providing a downloadable PDF version, making it convenient for readers to access the information on their own time. Their dedication to crafting stunning visuals is evident in every aspect of the project.

From the vibrant colors to the seamless navigation, everything has been meticulously designed to leave a lasting impression on the viewer. And with clickable links that make exploring the content a breeze, the user experience is guaranteed to be nothing short of exceptional.

The thing is, your case study presentation won’t always sit on your website. There are instances where you may need to do a case study presentation for clients, partners or potential investors.

Visme has a rich library of templates you can tap into. But if you’re racing against the clock, Visme’s AI presentation maker is your best ally.

15. How Cents of Style Made $1.7M+ in Affiliate Sales with LeadDyno

Cents of Style had a successful affiliate and influencer marketing strategy. However, their existing affiliate marketing platform was not intuitive, customizable or transparent enough to meet the needs of their influencers.

Cents of Styles needed an easy-to-use affiliate marketing platform that gave them more freedom to customize their program and implement a multi-tier commission program.

After exploring their options, Cents of Style decided on LeadDyno.

LeadDyno provided more flexibility, allowing them to customize commission rates and implement their multi-tier commission structure, switching from monthly to weekly payouts.

Also, integrations with PayPal made payments smoother And features like newsletters and leaderboards added to the platform's success by keeping things transparent and engaging.

As a result, Cents of Style witnessed an impressive $1.7 million in revenue from affiliate sales with a substantial increase in web sales by 80%.

LeadDyno strategically placed a compelling CTA in the middle of their case study layout, maximizing its impact. At this point, readers are already invested in the customer's story and may be considering implementing similar strategies.

A well-placed CTA offers them a direct path to learn more and take action.

LeadDyno also utilized the power of quotes to strengthen their case study. They didn't just embed these quotes seamlessly into the text; instead, they emphasized each one with distinct blocks.

Are you looking for an easier and quicker solution to create a case study and other business documents? Try Visme's AI designer ! This powerful tool allows you to generate complete documents, such as case studies, reports, whitepapers and more, just by providing text prompts. Simply explain your requirements to the tool, and it will produce the document for you, complete with text, images, design assets and more.

Still have more questions about case studies? Let's look at some frequently asked questions.

How to Write a Case Study?

• Choose a compelling story: Not all case studies are created equal. Pick one that is relevant to your target audience and demonstrates the specific benefits of your product or service.
• Outline your case study: Create a case study outline and highlight how you will structure your case study to include the introduction, problem, solution and achievements of your customer.
• Choose a case study template: After you outline your case study, choose a case study template . Visme has stunning templates that can inspire your case study design.
• Craft a compelling headline: Include figures or percentages that draw attention to your case study.
• Work on the first draft: Your case study should be easy to read and understand. Use clear and concise language and avoid jargon.
• Include high-quality visual aids: Visuals can help to make your case study more engaging and easier to read. Consider adding high-quality photos, screenshots or videos.
• Include a relevant CTA: Tell prospective customers how to reach you for questions or sign-ups.

What Are the Stages of a Case Study?

The stages of a case study are;

• Planning & Preparation: Highlight your goals for writing the case study. Plan the case study format, length and audience you wish to target.
• Interview the Client: Reach out to the company you want to showcase and ask relevant questions about their journey and achievements.
• Revision & Editing: Review your case study and ask for feedback. Include relevant quotes and CTAs to your case study.
• Publication & Distribution: Publish and share your case study on your website, social media channels and email list!
• Marketing & Repurposing: Turn your case study into a podcast, PDF, case study presentation and more. Share these materials with your sales and marketing team.

What Are the Advantages and Disadvantages of a Case Study?

Advantages of a case study:

• Case studies showcase a specific solution and outcome for specific customer challenges.
• It attracts potential customers with similar challenges.
• It builds trust and credibility with potential customers.
• It provides an in-depth analysis of your company’s problem-solving process.

Disadvantages of a case study:

• Limited applicability. Case studies are tailored to specific cases and may not apply to other businesses.
• It relies heavily on customer cooperation and willingness to share information.
• It stands a risk of becoming outdated as industries and customer needs evolve.

What Are the Types of Case Studies?

There are 7 main types of case studies. They include;

• Illustrative case study.
• Instrumental case study.
• Intrinsic case study.
• Descriptive case study.
• Explanatory case study.
• Exploratory case study.
• Collective case study.

How Long Should a Case Study Be?

The ideal length of your case study is between 500 - 1500 words or 1-3 pages. Certain factors like your target audience, goal or the amount of detail you want to share may influence the length of your case study. This infographic has powerful tips for designing winning case studies

What Is the Difference Between a Case Study and an Example?

Case studies provide a detailed narrative of how your product or service was used to solve a problem. Examples are general illustrations and are not necessarily real-life scenarios.

Case studies are often used for marketing purposes, attracting potential customers and building trust. Examples, on the other hand, are primarily used to simplify or clarify complex concepts.

Where Can I Find Case Study Examples?

You can easily find many case study examples online and in industry publications. Many companies, including Visme, share case studies on their websites to showcase how their products or services have helped clients achieve success. You can also search online libraries and professional organizations for case studies related to your specific industry or field.

If you need professionally-designed, customizable case study templates to create your own, Visme's template library is one of the best places to look. These templates include all the essential sections of a case study and high-quality content to help you create case studies that position your business as an industry leader.

Get More Out Of Your Case Studies With Visme

Case studies are an essential tool for converting potential customers into paying customers. By following the tips in this article, you can create compelling case studies that will help you build trust, establish credibility and drive sales.

Visme can help you create stunning case studies and other relevant marketing materials. With our easy-to-use platform, interactive features and analytics tools , you can increase your content creation game in no time.

There is no limit to what you can achieve with Visme. Connect with Sales to discover how Visme can boost your business goals.

Easily create beautiful case studies and more with Visme

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Forecasting & Time Series Analysis – Manufacturing Case Study Example (Part 1)

Today we are starting a new case study example series on YOU CANalytics involving forecasting and time series analysis. In this case study example, we will learn about time series analysis for a manufacturing operation. Time series analysis and modeling have many business and social applications. It is extensively used to forecast company sales, product demand, stock market trends, agricultural production etc. Before we learn more about forecasting let’s evaluate our own lives on a time scale:

Life is a Sine Wave

Time Series Analysis; Life’s Sine wave – by Roopam

I learnt a valuable lesson in life when I started my doctoral research in physics & nano-technology. I always loved physics, but during my doctoral studies, I was not enjoying the aspect of spending all my time in an isolated lab performing one experiment after another. Doing laboratory research could be extremely lonely. Additionally, I always enjoyed solving more applied and practical problems which I believed was missing in my research work. After getting frustrated for some time I decided to take some career advise from a trusted physicist friend. Before you read further, I must warn you that physicists as a community are usually mathematical, and occasionally philosophical. Physicists prefer to create a simple mathematical model about a complicated situation. They slowly add complexity to this simple model to make it fit with reality. The following is the key point I discovered during that conversation with my friend.

A simple model for life is a sine wave – where we go through ups and downs of moods and circumstances. Like a sine wave, we don’t spend much of our time either on the peaks or the troughs but most of our time is spent climbing up or sliding down. Now keeping these moods and circumstances cycle in mind, a perfect choice of career is where one could enjoy both climbs and slides – as the up and down cycle is inevitable in life.

Keeping the above in mind I prepared a list of keywords that I associated with a job that I can truly love to absorb the up and down cycle of life. The following is my list of keywords:

This prompted me to change my career from laboratory research to data science and business consulting. I am lucky that my career in data science and business analytics for over a decade has allowed me to check mark all these keywords.

Interference of Other waves

This is what is displayed in the adjacent chart where the product of four harmonic sine waves is an irregular shape at the bottom. Eventually, our actual lives’ function looks more like an irregular pattern produced through the interference of several sine waves.

Time Series Analysis – Decomposition

Now, let me try to create a connection between what we discussed above with time series analysis and forecasting. The fundamental idea for time series analysis is to decompose the original time series (sales, stock market trends, etc.) into several independent components. Typically, business time series are divided into the following four components:

• Trend –  overall direction of the series i.e. upwards, downwards etc.
• Seasonality – monthly or quarterly patterns
• Cycle  –  long-term business cycles
• Irregular remainder – random noise left after extraction of all the components  

Interference of these components produces the final series.

Now the question is: why bother decomposing the original / actual time series into components? The answer: It is much easier to forecast the individual regular patterns produced through decomposition of time series than the actual series. This is similar to reproduction and forecasting the individual sine waves (A, B, C, and D) instead of the final irregular pattern produced through the product of these four sine waves.

Time Series Analysis – Manufacturing Case Study Example

You will start your investigation of this problem in the next part of this series using the concept discussed in this article. Eventually, you will develop an ARIMA model to forecast sale / demand for next year. Additionally, you will also investigate the impact of marketing program on sales by using an exogenous variable ARIMA model.

Sign (Sine) off Note

Whether you like it or not, life inevitably goes through up and down cycle. A perfect career or relationship doesn’t make the variability disappear from our lives but makes us appreciate the swings of life. They keep us going in the tough times. They make us realise that variability is beautiful!

26 thoughts on “ Forecasting & Time Series Analysis – Manufacturing Case Study Example (Part 1) ”

Hi Roopam, i’m a follower of your blog for quite a time now, i believe this is your crown jewel till now, i have been working on time series analysis for the last 8 years and this is the best explanation for trend and rationale for decomposing Time series, keep it up and looking forward for your next blog.

Thanks Khalid! It’s flattering to receive such an adulation from a long term professional of time series analysis. Hope you will enjoy the remaining parts as well.

Thanks roopam. You explain things better than any book or person I have encountered. You really really get your stuff and I (along with many others) really appreciate your knowledge sharing. Your articles are the holy grail for those who really want to understand these concepts. You should write a book on machine learning algo’s explained. I’d buy it!

Thanks Jason,

I do have plans to write a book with hands on application of all the case studies on YOU CANalytics along with data, exercises, and R / Python codes. The idea behind this book is to recreate actual thought process and effort of real data science and business analytics projects. I will need to take a few months off my schedule to draft this book, hopefully you will see something soon.

is the book out soon?

For now it is all on this blog. Will update about the book once I start to work on it. Thanks for checking though.

Very nicely written article.

Really one of the best explanation. I am a huge fan of yours.

Thanks. nice approach about the decomposing time series model.

Very nice article! you got me on the “I must warn you that physicists as a community are usually mathematical, and occasionally philosophical”! I’ll be glad to help HorsePower! Looking forward for part 2! and to “Don’t settle”!

BR. Antoine

Great explanation Roopam…

I follow your blog actively. I consider the time series to be the most complicated to understand and implement in a more practical way. While doing forecasting, is there any way to get into account external interference as well? In this case, can we factor in drought conditions and sudden war or even currency exchange? Hoping to clear all my apprehensions and putting the knowledge into practical use. I am hoping to buy your book soon 🙂

Thanks Bharath,

It is possible to incorporate external factors in a time series model, however sudden war and draught are one-off events and hence you would rather not include them in the final model but study their overall effect on variable of interest (say pre and post tractor sales). Other regular interval variables like currency exchange make much more sense in the model. We will study one such variable i.e. marketing expense in latter parts of this case.

Hi Roopam, Your blog is really great way to learn analytics. You connect the concepts behind various statistical techniques to life in a easy way. I often find books making these concepts difficult to understand and creating a disconnect between analytics professional and stakeholders (users) of analysis. Looking forward for your book.

Wow. I just found out your blog, and love it! So much to learn, and so much insights. Thank you for the great article.

I love the Blog!

Excellent article ….

Hello Roopam Sir….I definetly think you should make a youtube channel on predictive analytics. I am sure people like me who aspired to be data scientist and predictive modelling expert will learn a lot from it.

Thanks, Vikrant. Will keep this in mind. You might see something soon.

Hie Roopam!!

It is great pleasure to have accessed your resourceful blog on Time Series Forecasting using R. Your blog is so unbundling of the so much complex issues of time series analysis.

I am working on some rainfall time series data (annual totals) for 58 years. I want to model using ARIMA and have plotted the time series (original series) and it looks that the series is trend stationary. I further fitted a regression line and it shows a slight declining trend from the mean but insignificant. The ACF and PACF plots both show negative significant spikes at lag 6.

I further tested for stationarity of the series using KPSS and ADF and both give p-values greater than 0.05. I also performed the Box test and obtained a higher p-value. The auto.arima suggested that the model is just white noise, AR(0,0,0) Fitting the model using these parameters, I obtained just the intercept and s.e. and when I tried to get the summary of the fitted model, i obtained an output: fit1<-arima(annual_series2, order = c(0 ,0 ,0), method = "ML", include.mean = TRUE) fit1 summary(fit1) Call: arima(x = annual_series2, order = c(0, 0, 0), include.mean = TRUE, method = "ML")

Coefficients: intercept 986.3241 s.e. 26.1365

sigma^2 estimated as 39621: log likelihood = -389.32, aic = 780.65

Training set error measures: ME RMSE MAE MPE MAPE Training set NaN NaN NaN NaN NaN Warning message: In trainingaccuracy(f, test, d, D) : test elements must be within sample

*** What does this mean? Do I need to specify the number of observations to be used, I mean specify maximum number of lags when fitting the model?

And the ACF of residuals of the the fitted model still indicate a negative significant spike at lag 6

My questions are:

1. How do I use the ACF and PACF plots of the original series to choose the model parameter? should I attempt differencing the series? 2. From which, ACF or PACF are the possible model parameters identified, I mean AR(p, d, q) 3. When forecasting, if the series is made stationary by whatever method, what series should I use to forecast? The original or the last order of making the series stationary?

Help me please

I would appreciate if you email me to [email protected]

Thanks in advance

Hi Rupam, very nicely written article. Is is possible to get the sales data used in the example in Excel (text) file format?

I am not conversant with R or SPSS, but familiar with excel. I teach first year and second year MBA students the basics of forecasting.

As a teaching tool, I want to create spreadsheet to show to students how ACF and PACF are calculated. With the data, I can actually reconstruct ACF, PACF diagrams for students and also let them play with spreadsheet and get a feel of the whole process.

Thanks and Regards Amol

excellent article on time series analysis.

Hello Roopam,

Just wanted to thank you for your excellent blog! I like the creative story you wrap around the methodology and listing of the mechanics (in R).

Hi Roopam, I am very new to data science field and trying to start my career in this field.Due to this i was going through so many articles online since almost last 60 days. But to my surprise the way you explained the concepts of breaking a bigger problem into smaller ones wrt data science is remarkable. I must say its so easy that anyone can understand it and in my opinion the person who uses the language which is easy and can be understood by many have the basic concepts very clear. Pls keep on sharing ur knowledge it can help many. Regards, Chiranjiv

Hi Roopam, You have a great blog going on here. Most of the stuff out there on the internet is basic and helps aspirants in Data Science domain. But your blog is very useful for working professionals and I am glad that you have put it up together because people often forget that the ones who are actually working also require help to revisit certain topics. Keep it up

I am a fan of your storytelling. Keep up the amazing work

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Top AI Use Cases in Manufacturing for 2024

Discover how AI transforms manufacturing with demand prediction, product design and development, smart automation, predictive maintenance, and real-time quality control. Explore how AI can cut costs, reduce downtime, and unlock new possibilities in your manufacturing processes.

Table of Content

1. demand forecasting for strategic decisions, 2. product design and development for valuable insights, 3. ai-driven supply chain optimization for revenue management, 4. quality control and defect detection, 5. predictive maintenance for equipment and factory automation, meet the demands of the ever-changing manufacturing industry with ai.

The world has changed for manufacturers. Preparation for uncertainty is now the industry norm, and businesses face various challenges such as climate change effects, geopolitical tensions, supply chain vulnerabilities, and technology breakthroughs.

 An MIT study indicates that the impact of such disruption is projected to increase by 15% to 25% in the next five years, making the manufacturing industry both dynamic and competitive.

 With the rise of Artificial Intelligence-driven technologies and tools like the Internet of Things (IoT), edge computing, and Machine Learning (ML), manufacturers have access to more data than ever before, enabling them to take more meaningful actions.

 Research shows that the global AI in manufacturing market is poised to be valued at $20.8 billion by 2028, with the top contributing factor being AI. And while there’s no shortage of AI applications in smart manufacturing methods, below are some of the most exciting use cases:

Let's build an AI-powered manufacturing system!

Top 5 use cases of AI in manufacturing

In the manufacturing sector, overproducing goods ties up capital in excess inventory. On the other hand, under-production leads to stockouts and lost sales. What if there was a way to optimize production schedules and manufacture only the right quantities at the right time?

Imagine being able to predict exactly what customers want, when they want it—without the risk of overproduction or underproduction—how would that change business operations?

Analyze vast amounts of historical data, including seasonal trends, past sales, and buying patterns, with AI-driven Machine Learning algorithms to predict future demand for products with a high degree of accuracy.

The technology also incorporates external factors, such as indicators of the digital economy, market trends, and social media sentiment. This meticulous approach enables forecasting models to account for broader influences that might increase product demand.

At the same time, AI systems can process real-time data inputs, such as sudden market fluctuations, supply chain disruptions, or unexpected events, equipping manufacturers to adjust their production plans to better respond to changing demand patterns.

Demand forecasting results in better resource management, improved environmental sustainability, and more efficient operations.

 The look and feel of a product are vital aspects of manufacturing operations. Specific parameters such as material type and weight, strength requirements, and code constraints must be considered.

With Generative AI, manufacturers can explore all possible configurations, often identifying innovative structures and designs that human counterparts might not consider. This process helps in optimizing product performance and machine usage.

Food for thought: What if there was a way to uncover design possibilities never even considered before?

Once the design is generated, AI-driven simulation tools can virtually test it under various conditions, such as stress, temperature, and vibration, to understand how a product will perform in the real world.

This proactive approach eliminates the need to create physical prototypes while pushing the boundaries of traditional design thinking and reducing costs with material usage optimization. It also enables modern manufacturers to bring new products to market much faster.

A manufacturer’s supply chain is a critical business process that influences the success or failure of customer experience. A high-performing supply chain management enables operational efficiency and responsiveness. Therefore, choosing the right supplier is crucial.

Thankfully, with AI, manufacturers can streamline the selection and evaluation of suppliers by analyzing various factors, such as cost efficiency, reliability, lead times, and past performance. They can find one that enhances supply chain sustainability goals without compromising profitability.

In addition, manufacturers can forecast demand for raw materials and components with AI-driven advanced analytics to maintain optimal inventory levels. This leads to faster production cycles, better inventory management, and more reliable delivery schedules.

Lastly, when traffic patterns, fuel cost savings, and delivery deadlines are studied closely with AI for route optimization so that products can reach retailers (and customers) on time, resulting in higher customer satisfaction levels.

So, let’s say manufacturers have used AI to make accurate demand forecasts. They’ve also designed and developed the product most efficiently and even streamlined their supply chains. But is that enough for a manufacturer to thrive? Not quite.

Product quality control and defect detection are just as important. Even if products are delivered on time, poor quality can still ruin the customer experience, decreasing customer engagement and potentially halting a manufacturer’s profits.

The good news is that AI-powered computer vision systems can inspect products on the production line at high speed, identifying defects, such as flaws in size, shape, color, or surface finish, with accuracy that far hoodwink human oversight.

These systems leverage deep learning models trained on large datasets of defective and non-defective items. AI can also be integrated with IoT sensors to continuously monitor production processes and quality control checks.

For example, sensors placed on manufacturing equipment can detect deviations in temperature, pressure, or other critical parameters in real-time, catching quality issues before they lead to significant product defects and increased carbon footprints.

End result? Improved product quality, reduced wastage, and happier customers.

Mining, metals, and other heavy industrial companies lose 23 hours per month to machine failures , costing $4,312,500. This figure raises a good point—what kind of savings manufacturers could make by applying techniques, such as predictive maintenance, to reduce unplanned downtime.

Sensors embedded in equipment, for example, can collect data to monitor various parameters, such as temperature, vibration, pressure, and noise levels. ML models analyze this data to detect patterns or anomalies indicating impending equipment failures.

AI can also use digital twins to simulate different maintenance scenarios, minimizing maintenance costs without interrupting actual operations.

A digital twin is a virtual replica of physical equipment that mirrors its real-time monitoring conditions. This digital transformation helps identify the most effective maintenance actions, predict the impact of various interventions, and plan for long-term equipment performance.

Plus, when equipment isn’t maintained promptly, businesses expose their workers to safety hazards, which can cause serious injuries, legal risks, and potential shutdowns, ultimately harming the workforce and the manufacturer’s reputation.

Is the downtime cost or the risk to human worker safety worth it? With AI, there’s no need. Innovative AI-powered maintenance systems help maintenance teams counter these dangers.

For example, GE’s Predix platform, Siemens’ MindSphere, and IBM Maximo help businesses delay the need for expensive equipment replacements and ensure they operate at peak efficiency.

Streamline your manufacturing processes with AI-driven solutions!

The critical thing is manufacturers must enable an AI-driven culture. To meet this goal, they must build trust in data and AI-driven algorithms by educating the workforce about AI capabilities and values. They must also embrace its risks and limitations.

For instance, data security is a significant concern, as the vast amounts of data generated and analyzed must be protected from breaches. Additionally, workforce training ensures everyone is equipped to work alongside AI-driven systems.

A phased implementation strategy, starting with pilot projects to gradually scale AI adoption, should also be considered.

What if we told you we had the know-how to create a compelling vision of effective human-machine collaboration in manufacturing processes?

As a professional and powerful AI app development partner , Intuz can help your manufacturing business drive change with the right AI methods and technologies.

Enhance your manufacturing efficiency with our AI-powered solutions for quality control, predictive maintenance, and supply chain optimization. Achieve operational excellence with AI-driven tools. Make data-driven decisions to drive the business forward.

Book a free consultation today and receive a complimentary AI integration roadmap tailored to your needs.

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Conversion Rate Optimization (CRO) Case Studies: 5 Best Examples

Marcin Hylewski

CRO case studies showcase successful optimization strategies implemented based on data-driven analyses. They provide a solid grasp of knowledge for digital marketers complaining about insufficient traffic, low user engagement, lack of quality leads, and, therefore, poor conversion rates. Did you know that a sole mobile optimization, being only one conversion rate optimization element, can improve conversion rates by 27% , as reported by Invesp?

Although companies currently allocate just $1 to optimizing conversion rates for every $92 spent on acquiring customers , this is shifting rapidly . Based on Google Trends data, Matomo indicates that CRO is one of the fastest-growing topics .

In this article, we present 5 most insightful conversion rate optimization case studies across different digital marketing channels to drive inspiration for your future optimization strategies and interventions.

Key Takeaways:

• conversion rate optimization examples described in case studies are mines of knowledge for marketers trying to boost conversion rates,
• an extensive conversion optimization report is able to provide valuable insights into what works in real-world scenarios, which helps marketers understand successful strategies and apply these lessons in their own activities,
• CRO emphasizes data-driven decision-making by analyzing visitor behavior to ensure that changes made are statistically significant and directly impact conversion rates,
• by learning from conversion optimization case studies, marketers can avoid common pitfalls and make more confident decisions that are likely to convert visitors into potential customers.

Let’s get into it!

What is Conversion Rate Optimization (CRO) Case Study?

A conversion rate optimization (CRO) case study is an in-depth analysis that examines how specific strategies and techniques were applied to improve the conversion rate on a website or landing page . They explore the steps taken to enhance user experience, messaging, design, and other elements that impact conversion, providing a detailed account of the challenges faced, the actions implemented, and the resulting outcomes.

The most comprehensive digital marketing case study (also CRO case studies) includes several key elements that detail the process, strategies, and outcomes of a marketing campaign. These elements are crucial for providing a versatile analysis and insight into the effectiveness of the campaign. Here is the full list.

• Introduction : Overview of the company, industry, and the specific challenges they were facing before the campaign began.
• Objectives/Goals : Clearly defined goals the company aimed to achieve through the digital marketing campaign, such as increasing website traffic, boosting sales, or improving brand awareness.
• Target Audience : Description of the intended audience, including demographics, interests, and online behavior.
• Strategy : Detailed explanation of the digital marketing strategies implemented, such as SEO, PPC, social media marketing, content marketing, email marketing, and more.
• Tactics : Specific actions taken within each strategy, such as keyword optimization, ad placements, social media content creation, or email campaigns.
• Implementation : Timeline and steps followed to execute the strategy, including tools and platforms used.
• Results : Quantitative data showing the outcomes, such as increased traffic, improved conversion rates, higher sales, or better ROI. This section often includes charts or graphs for clarity.
• Analysis : In-depth examination of the results, explaining why certain tactics worked or didn’t work, and the lessons learned from the campaign.
• Conclusion : Summary of the overall success of the campaign, key takeaways, and recommendations for future strategies.
• Client Testimonial : Feedback from the client on the effectiveness of the campaign and the impact on their business.

Of course, sometimes case studies lack a few of the above-mentioned elements, especially customer testimonials or distinguishing strategies and tactics, but generally, the content and structure are similar (even if the order of individual parts is different from the one presented).

CRO case studies are valuable across various use cases. Companies can utilize them for benchmarking , allowing them to compare their own conversion metrics against industry best practices. They are also essential for strategy development , providing marketers with insights and inspiration to craft or refine their optimization plans. When businesses face specific conversion challenges, case studies offer problem-solving solutions by illustrating how similar issues were successfully addressed. Finally, CRO case studies serve as excellent training and educational tools , helping teams learn and implement effective optimization techniques based on real-world examples.

In digital marketing, most valuable benefits related to exploring case studies include:

• practical insights : CRO case studies provide actionable insights backed by real-world data, helping you understand what works and why;
• risk reduction : learning from others’ successes and failures allows to avoid common pitfalls and implement proven strategies;
• inspiration for experimentation : CRO case studies often highlight innovative approaches that can drive inspiration for experimenting with different conversion strategies;
• data-driven decision making : by analyzing detailed outcomes, you can make more informed, data-driven decisions when optimizing your own website or landing page.

Finally, it’s good to know that case studies (CRO case studies, too) also serve marketing purposes . Success stories build credibility for companies that implemented strategies and actions, which finally increased conversions.

5 Best Conversion Rate Optimization Examples

Let’s now jump into practice and explore a few real case studies that resulted in increased conversions. We’ll demonstrate successful CRO strategies implemented for different digital channels, from landing pages, through homepages, classical websites, and app stores to e-commerce sites.

1. Going (Landing Page CRO)

Going is a company that delivers extra deals from its partners to people planning travel. To refine its landing page conversion strategies, they undertook an A/B testing initiative with CTA copy triggered as a potential game-changer.

The primary goal of this experiment was to determine whether a small change in the call-to-action (CTA) on Going’s homepage could lead to an increase in the number of users starting a free trial of their premium plan. The test aimed to validate the hypothesis that showcasing the full value of the premium offering would encourage more users to convert from free to paid memberships.

Challenges to Tackle

Despite having a solid business model, Going faced the challenge of converting free users into paying customers. The existing strategy relied on users signing up for a limited free plan, with the hope that they would later upgrade to a premium version. However, this approach did not fully showcase the advantages of the premium service, potentially limiting its appeal.

Actions/Strategies

To address this challenge, Going’s team conducted a simple A/B test. They tested two variations of the CTA on their homepage:

• Variation A: “Sign up for free” (existing CTA)
• Variation B: “Trial for free” (new CTA)

The only difference between the two versions was the CTA wording, with the intention of determining whether offering a free trial of the premium plan would result in higher conversion rates.

The results of the A/B test were substantial, demonstrating the impact of even minor changes in marketing strategy:

• 104% increase in trial start rate month-over-month,
• conversion rate through paid channels surpassed that of organic channels for the first time,
• enhanced ability to allocate media spend effectively due to improved conversion rates

Lessons learned

A/B testing can be a powerful instrument for increasing conversions on landing pages. If you already have a hypothesis of what element on your page requires improvement, A/B tests allow you to check on real audience which changes are the most effective . Sometimes, even minor tweaks with minimal effort on your end can provide a substantial rise in the number of leads and conversions.

2. Archive Social (Homepage CRO)

ArchiveSocial, a company specializing in social media archiving solutions, embarked on a strategic conversion rate optimization (CRO) journey to enhance user engagement and drive higher conversions through their homepage and ‘Request Demo’ page.

The primary objective for ArchiveSocial was to improve two critical performance indicators: lead generation and conversions. The focus was on refining the user experience across key pages, particularly the homepage and pricing page, to increase visitor engagement and guide them towards taking desired actions.

The analysis revealed several areas for improvement that were hindering the user experience:

• low visibility of CTA on the homepage: the email form wasn’t standing out, blending in with the rest of the content and failing to attract attention;
• complexity of pricing options: the pricing page was cluttered, making it difficult for visitors to make quick and informed decisions about which plan to choose;
• underutilized resources section: the ‘Resources’ section was not easily accessible, limiting its potential to engage visitors further along their journey.

To address these challenges, the company implemented a series of targeted A/B tests aimed at enhancing the user experience and increasing conversion rates:

• Testing homepage CTA improvements The first test focused on increasing the visibility of the primary form field and call-to-action (CTA) on the homepage. The CTA button was redesigned with a distinct color and repositioned within the first fold of the page. Scrollmaps were utilized to monitor how these changes affected user interaction.
• Testing pricing page tweaks In the second test, the emphasis was on improving the click-through rate across the pricing plans. This was achieved by simplifying the plan options and highlighting the primary CTA, making it easier for visitors to navigate towards the ‘Thank You’ page.
• Testing enhancements for “Resources” section The third test explored the hypothesis that placing the ‘Resources’ section in the top navigation bar would boost engagement. This change aimed to create a more intuitive and seamless visitor flow towards valuable content that could assist in their decision-making process.

The systematic approach to CRO testing led to impressive results for ArchiveSocial:

• 101.68% increase in click-through rate,
• enhanced visibility and engagement with the primary CTA on the homepage,
• simplified pricing page resulting in smoother navigation and informed decision-making,
• improved access to the ‘Resources’ section, boosting visitor interaction,

Many optimization success stories prove that the most remarkable results are achieved with a combination of changes applied in one or several stages. Additionally, it’s noteworthy that while many marketers know that fewer form fields and shorter forms increase conversions, it’s even more important to make the form visible (just like CTA should be). Below you can compare Social Archive’s homepage after (version A) and before (version B) the form and CTA optimization.

3. Walmart Canada (Website CRO)

Walmart Canada embarked on a responsive redesign of their website, focusing on improving the user experience across all devices. Despite the challenges, their efforts led to a significant boost in conversions, particularly on mobile.

The primary goal was to create a fully responsive site that catered to all screen sizes, improving both the aesthetic and functional aspects of the user experience, especially on mobile devices. The previous design looked aged and was inadequate for the youngest generation of clients.

The main challenges included an outdated mobile experience with poor aesthetics and slow loading times. Additionally, the existing design didn’t effectively accommodate the growing number of mobile users.

Walmart Canada conducted extensive usability testing on both old and new designs. They implemented A/B testing to optimize various elements and focused heavily on improving site speed. By streamlining the interface and removing non-essential buttons, they enhanced the overall user experience.

Here is what they achieved:

• 20% increase in overall conversions across all devices,
• 98% increase in mobile orders,
• simplification, such as removing the “View Details” button for unavailable products, significantly boosted conversions.

Lessons Learned

This case illustrates the profound impact that a well-executed responsive redesign can have on conversion rates, proving that even small adjustments can yield substantial results. It also clearly shows that mobile optimization is a must for businesses aiming at young visitors as a target audience . Below, you can see the current version of the Canadian Walmart’s homepage, which is fully responsive (mobile view on the right).

4. Ampere: Business Mobile Bank (App Store Optimization)

Ampere Business Bank is an innovative online banking platform designed specifically for businesses, providing a seamless way to manage multi-currency accounts, send and receive international payments, and access favorable currency exchange rates. Despite its comprehensive features and user-friendly approach, Ampere faced significant challenges in carving out a niche in a highly competitive market filled with well-established banking apps.

The primary goal of the promotional strategy was to expand its geographical reach, enhance app visibility, and increase the number of installations. Achieving these goals required a focused approach to App Store Optimization (ASO) to improve the app’s presence and attract a broader audience in an already saturated market.

Ampere Business Bank entered the App Store in September 2022. Gaining user trust and competing against nearly a hundred established banking apps was a significant hurdle, particularly within the financial sector, where credibility and reliability are paramount.

To address these challenges, the team employed a multi-step strategy leveraging the capabilities of RadASO Tech Boosted Solution, a proprietary automation tool that provides critical insights into competitors, search terms, and app positioning:

• Competitor identification and analysis: The team first identified apps with similar functionalities to Ampere Business Bank, focusing on those that posed the most direct competition. This analysis revealed key insights into competitor strategies, including preferred countries for promotion and markets with the highest installation rates.
• Localization strategy development: Recognizing the importance of localization in app visibility, the team set priorities based on countries where competitors had a significant number of installations. They expanded the app’s language offerings to include multiple locales, such as English (Canada), French (Canada), German, and Spanish (Spain), among others. This strategic localization allowed Ampere to resonate with a broader audience and improve its ranking in diverse markets.
• Semantic core collection: Utilizing the RadASO Tech Boosted Solution, the team rapidly compiled a comprehensive semantic core that included relevant search terms used by competitors, titles, subtitles, and search suggestions from the App Store. This approach ensured a more targeted use of keywords, replacing irrelevant terms that previously hampered the app’s search results.
• Metadata optimization for multiple locales: With the help of the Metadata Wizard, another tool within RadASO Tech Boost Solution, the team prepared optimized metadata tailored to each prioritized locale. They employed cross-locale techniques to ensure that metadata was effective across multiple regions within the same country, such as English and French in Canada or Spanish and Catalan in Spain. Key parameters, including Search Ads Popularity (SAP), app positioning, and competitor analysis, guided the prioritization of search terms to maximize visibility.

This optimization case resulted in incredible surges in conversion stats:

• number of won positions in the top 3 of App Store search results surged over 20% (the same, besides, went for positions 4-10),
• after a few weeks, app visibility increased for several countries over ten times (e.g., Canada, Australia, Netherlands, Pakistan),
• the number of installations increased over three times on average (for some countries there was over 10x increases),
• after 30 days, the number of downloads (which is the most significant conversion for the Ampere increased by over 100% (for Italy, it was over 200%, and for Canada, over 400%).

For IT firms and SaaS companies, software and customer satisfaction, as well as brand recognition, are three precious items that should be handled with utmost care. You may have the best product on the market, but if it is invisible or doesn’t satisfy users for some reason (e.g., too high price, poor support, unstable infrastructure), other businesses will outperform you with ease. Thus, it’s of great importance to constantly monitor and refine how it is marketed, promoted, and sold . Based on data and professional expertise, not your private impressions, which may be biased and/or misleading. Here is what the Ampere app store site looks like currently:

5. daFlores (E-commerce CRO)

In the highly competitive online floral industry, optimizing an online store or ecommerce conversion rate can have a significant impact on sales and overall business performance. Conversion Rate Experts, a renowned CRO agency was hired by daFlores, a leading online flower delivery service, to enhance their store’s user experience and increase conversions.

The primary goal of the project was to increase daFlores’ conversion rate by identifying and addressing key barriers in the user journey. The focus was on providing brand’s credibility through utilizing social proof, and making website more user-friendly, improving customer engagement, and ultimately driving more sales.

daFlores faced several challenges in optimizing its eCommerce site, particularly given the multilingual and international nature of its audience:

• Diverse customer base: The site needed to cater to visitors from multiple countries, speaking different languages, each with their own specific needs and objections.
• Unclear delivery information: Many visitors were unsure about delivery times, which led to hesitation and order abandonment, especially for urgent orders.
• Credibility issues: Some new visitors were unfamiliar with daFlores and were hesitant to trust the service, which impacted conversion rates.
• Technical complexity of changes: Implementing changes on an eCommerce platform can require significant technical resources, so changes had to be carefully selected based on their likelihood of success.

To tackle these challenges, Conversion Rate Experts conducted extensive user research and implemented specific tests to address identified objections:

• Objection Collection and Analysis The team started by identifying visitor objections using multiple research methods. These included surveys, live chat transcript analysis, customer support feedback, and session recordings. By analyzing this data, they pinpointed key concerns, such as uncertainty about delivery times and trust issues, which were preventing conversions.
• Urgency Enhancement: Adding a Countdown Clock To address concerns about delivery times, the team introduced a countdown clock on category pages with the message: “Order in the next n hours for delivery today.” This small addition not only informed customers about same-day delivery but also created a sense of urgency, encouraging them to place their orders immediately.
• Building Credibility with Social Proof To enhance trust, a static image highlighting daFlores’ 600,000+ Facebook followers was added to the header. This simple proof element conveyed popularity and customer satisfaction, reassuring visitors of the company’s credibility.
• A/B Testing for Validation All changes were rigorously tested using A/B testing methods to ensure they positively impacted conversion rates. Split-testing tools like Visual Website Optimizer were employed to compare the performance of the original site with the modified versions, validating the effectiveness of each change.

The implementation of these targeted strategies led to substantial improvements in daFlores’ conversion rates:

• 27% increase in orders due to the urgency created by the countdown clock
• 44% uplift in sales by adding the Facebook “Likes” image, which boosted credibility and trust
• Enhanced user experience by directly addressing customer objections uncovered through research
• Increased engagement and reduced bounce rates on key landing pages

The daFlores case study offers many valuable lessons on the importance of user research and targeted CRO strategies, but three seem to be the most essential:

• First, gaining insights through comprehensive user research is essential . By understanding the unique objections and concerns of your audience, you can craft targeted solutions that directly address their needs. Utilize a range of research methods, such as surveys, live chat analysis, and session recordings, to uncover hidden barriers to conversion.
• Second, it’s crucial to validate all changes with A/B testing to ensure statistical significance. This data-driven approach allows you to determine which adjustments genuinely impact conversion rates, preventing wasted effort on ineffective strategies. Small changes, such as adding urgency elements like countdown timers or leveraging social proof, can make a significant difference when backed by solid data.
• Lastly, remember that CRO is not just about tweaking visuals or copy – it’s about increasing revenue by enhancing the entire user journey . Prioritize changes that simplify the purchasing process, build trust, and make the experience more intuitive. Adopting a diagnosis-and-prescription approach, rather than relying on generic tactics, will help you achieve meaningful, long-term results in your optimization efforts.

Conclusions

As you see, a typical conversion rate optimization case study is all about improving digital marketing strategies, tactics, and tools for better business or overall marketing outcomes. The educational part is done, now it’s time to apply your knowledge in practice. Draw inspiration from the strategies outlined in the analyzed conversion rate optimization case studies and reflect on how applying them could benefit your business.

Landingi is a perfect tool to be your first touchpoint with a practical CRO. It is equipped not only with a super-simple yet very versatile landing page builder requiring no coding skills but also a bunch of optimization tools for various purposes. Let’s mention the most popular ones:

• A/B testing enables you to experiment with different design elements to see which performs better. For example, you can present two variants of your landing page (usually, they are very similar, yet with one significant difference, e.g. in headline or CTA content, number of fields in the form, etc.) to users for two weeks to see which one is more effective in lead generation.
• EventTracker  allows you to track how your site visitors behave , where they click (and how often), to what point they scroll, which elements (forms, videos, images, CTAs, etc.) engage them most, and so on. This provides a solid data foundation for your future design decisions, hopefully boosting conversions.
• AI package gives you a set of tools for streamlining content creation or recreation – from generating copy for your pages to completing SEO parameters and simple image editing. This way, you can deliver more targeted content with minimal effort and ultimately much quicker, which can result in more traffic, more leads, and, as a result, more sales.
• Translations arm you with capabilities for generating content in various languages quickly . This way, you can instantly create whole pages in different languages to expand to new markets or audiences or even go global.

With these solutions, you can easily increase landing page conversions and the conversion rates of your entire online marketing campaigns involving landing pages.

And to top it all off, Landingi currently offers a free plan or  14-day trials  for paid plans, which is perfect also for learning to build landing pages and optimize them for higher conversion rates. See more details on our pricing page. Good luck!

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