JPR Track Record and Case Studies
JPR is a boutique consultancy that applies industrial engineering principles expertly and rapidly, in manufacturing and
service industries. JPR's value is to select and utilize the appropriate techniques and tools,
tailored to the client's specific objectives, timing, and budget.
Call Jack Greene
at 843-422-1298 or
JPR, with Jack Greene as the president, applies the knowledge of forty years experience in Industrial Engineering practice and theory
to today's businesses, large and small, to achieve a better way; to use resources, space, time,
labor, people in order to reach greater efficiencies, better work flow and ultimately increased profitability.
He has headed division or corporate industrial engineering for three Fortune 250
companies; ITT, Abbott Labs, and Bausch & Lomb, before founding JPR in 1992.
Jack Greene has implemented dozens of productivity
improvement, work measurement, cost reduction, expansion, relocation, consolidation and integration projects in the US and
internationally for manufacturing companies both large (FORTUNE 250) and small.
In all of the management positions, he has directed industrial engineering (productivity, work measurement, cost standards, methods,
layout) and facility planning (capacity and cost determination to support strategic decisions, justification of projects, subsequent
planning and implementation, plant expansion, relocation, consolidation).
His expertise in cost effective manufacturing and management practices comprehends the semiconductor, pharmaceutical, optical, steel,
lighting, electronic assembly, food, recreational, consumer products and communication industries. He has frequently represented
manufacturing and facility interests within due diligence and feasibility studies for merger, acquisition and consolidation projects.
Adept in all aspects of facility planning, Jack Greene has successfully completed more than three dozen manufacturing, distribution
center, R&D, and administration projects, reaching cost effective expansion, relocation, acquisition, consolidation, site search,
and capacity increase objectives.
Case studies follow in order, for Work Measurement Time Study; Plant Layout; Cost Reduction;
Service Industry; Corporate Relocation; Mergers.
Work Measurement Case Studies
motion and time study, work sampling
Objectives: Raise output, establish manning levels, balance work, predict output, create an engineered basis for cost
definition and control, meet the Sarbanes-Oxley Act. Quite frequently JPR provides objective time study of disputed circumstances,
management - union perhaps or plant / headquarters.
A manufacturer with 250
unionized employees wanted to quantify product costs but had no usage information for labor or variable material and overhead. JPR measured
the work performed with watch and work sampling, then compiled expectations for each workstation. JPR led the development of a product
costing system for labor and variable overhead factors, create an engineered basis for cost definition
and control to meet their auditor's requirements and Sarbanes-Oxley Act provisions. Rhode Island
A manufacturer planned an
across-town relocation of six production lines, and expected a better layout to cut labor cost. JPR used time study and work sampling
to confirm the expectations for direct and maintenance operators.Texas
A manufacturer with a
thousand people and two major product lines relocated half of production to another plant. JPR compiled standard methods descriptions, balanced and
measured the work, established manning
levels, and predicted output for manufacturing and distribution at the new location. New York
A distributor slimmed down
the product line and placed it in another location. In the relocated operation, JPR measured the put away and pick work, assigned work, determined
output rates, balanced lines, and set manning levels. Texas
JPR time studied operations in a highly
automated facility to provide
objective workload data for a quality inspector, and resolve a union - management disagreement. The work level was out of balance during the shift,
heavily front-loaded, From the
observatons, the extent of each of the work elements was clear. We
recommended actions especially of scheduling and timing, to resolve the issue. California
A regular client requests periodic visits to plants, to quantify workloads of manufacturing line crew members
in advance of union contract negotiations.. I am also
requested to review individual workloads, in cases of grievance or a major change in technology. If a workload is high or unequal, the workload analysis always
indentifies a practical solution to rebalance the activity. Oklahoma and Texas.
For an on-line medical billing company, revised outdated practices and rates for an employee incentive plan, standardized practices across departments, improved output.
Developed group incentives for a processor of returned and surplus merchandize, streamlined the receiving process,
reduced rehandling by better, though still largely manual, material handling and workplace methods. Mississippi
Plant Layout and Facility Design Case Studies
Objectives: Fit the space to the need, improve flow and space utilization, add in new products or processes.
JPR set up a relocated
product line in an existing 70,000 square foot plant, and later expand operations by half in an expansion. In this project, we served as project manager
to add a 70 K foot warehouse, on budget, in four months. We planned the new layouts, the equipment transitions, and reinstallation.Texas
JPR laid out metal working
shop equipment, assembly operations, product flow process, material storage locations, product shipping, support and admin space to
consolidate two manufacturing plants into one, in Pennsylvania.
JPR created a production sunglass operation from acquired equipment, planned the layout,
relocated into a leased facility, and set up operations. Texas
JPR assessed and modified a production layout for a major consolidation and upgrade,
in order to meet a corporate strategy for a third-party consumer products firm, in Tennessee. The layouts allowed the client to create a modern plant,
designed to feature the sophisticated tecnology and quality emphasis to appeal to visiting clients and their customers.
At a U. S. Naval Air Station, JPR developed layout options for a prototype
design and manufacturing shop. The old layouts did not match current requirements, and had continually added equipment into existing buildings.
This facility featured sophisticated modern manufacturing equipment, and wanted to showcase it for clients. Our layouts met the requirements,
as well as provided more efficient use of space and better flow, in Maryland.
JPR helped a cleaning products company to resolve an acute
space shortage, and to plan for long term expansion.The result created a high priority plan to free up space, and further
actions for lower priority permanent operating solutions such as creating space throughout the operation, reduced material handling especially
multiple handling, and use of leased facilities. We suggested options for expansion, on site or in another location. Tennessee.
Analyzed steel warehouse handling and identified where storage should be
located to optimize access, and minimize crane and loader travel. Time studied as well to learn time lost to interference, and crew workloads over 24 hours. Mid-Western sites.
Cost Reduction, Productivity Improvement Case Studies
Objectives: Simplify and standardize workplace methods,
mprove product and people flow, identify and manage constraints, reduce cycle time and inventory; using classic and modern techniques.
A manufacturer had a production
line with a product cost that was too high to make new contracts profitable, and was about to close the line. The product marketing
manager asked JPR to come in, and he worked on the production floor with us. JPR measured times, manning, and costs, identified delay,
and relieved constraints. The marketing manager judged priorities and related improvement to product cost. Together we increased line output,
which, as it always does, pulled product cost down to the levels desired. South Carolina
As an electronic manufacturer
moved from prototype models into full production, JPR applied work measurement to balance production
line equipment and manpower, set crew sizes, and then to plan product flow, layout and expansion options. Virginia.
JPR improved product changeover times, and cleanup between products, in an OTC pharmaceutical environment.
We studied and evaluated prioritization, techniques, tools, crew balance and planning. We were able to achieve both fewer changes and shorter times,
which raised output for multiple production lines. Maryland and North Carolina.
JPR developed process flow,
methods, storage, workplace layouts, and labor pricing for a small warehouse to pick and distribute orders nationwide. South Carolina
Objectives: Service companies are as interested in productivity as
traditional manufacturing is. JPR applying productivity techniques to fit the particular circumstances .
Service Company Case studies
A luxury boutique hotel wanted to
quantify a fair daily room cleaning rate for its room attendants, maids. JPR time studied the work, defined patterns, determined the
required times per room for that particular hotal, identified potential cost reductions, (The number of pillows and the amount of glass cleaned are significant.)
Downtown Los Angeles
JPR found a new corporate
home for a service company who needed to grow, and preferred to do so where it could interact with a broader financial and technical
community, within a community whose quality of life appealed to management. Richmond, Virginia
JPR provided work
measurement information to a company who provides cleaning for building, including schools. The company, and school districts,
find a lack of objective measurement information;.The many variables do indeed suggest that each school is different., and should
develop their own rates for their geometry, equipment, and requirements. Chicago.
JPR time studied
the installation process for a product used in construction, and for the competitor's product under the same circumstances. We found objectively
that our client's installation time was indeed less than for the competitor's, and advised the manufacturer who
placed the information on the web pages. Georgia.
Observed new and developmental equipment in operation; time studied and work sampled crew workloads to optimize fast food operating capacity. and food quality and taste through shorter preparation cycles. New Mexico.
Corporate Relocation and Expansion Case Studies
HQ, office, manufacturing plant, distribution facility
Objectives: Hands-on actions to find another location in addition to or instead of, to relocate,
grow or consolidate, transfer technology.
JPR found sites for distribution and headquarters for a
newly acquired division; justified the expense, planned what was to be relocated, laid out two facilities, remodeled existing facilities,
planned and relocated equipment. Distribution in Texas; H. Q. in
JPR consolidated four pharmaceutical plants into two, converted layouts and arrangement from
antiquated facilities into modern ones, planned the transitions of selected equipment,
and over a period of time transferred pharmaceutical technology to Maryland and to North Carolina.
JPR consolidated three semiconductor manufacturing operations into one. The
project included evaluation of processes and equipment to determine what to integrate; then layouts plans to consolidate operations, then movement of
equipments, material and processes into a Florida plant, then shut down California and Massachusetts facilities,
JPR relocated a division of Corning Glass from Pennsylvania to Florida after it was
acquired. We inventoried equipment and material, determined what to integrate and what to store, planned the new location layouts, physically
transferred the division equipment.
JPR developed block layouts and a Master Plan to consolidate facilities on
three properties onto one; short term actions to expand and integrate operations for efficiency, to rearrange space to relieve crowding,
and to accomodate growth in new products; in Tennessee.
JPR evaluated sites and construction options for the
developing film industry , specifically large sound stages, in South Carolina. At several locations in the Low country, developed drafts of
potential building arrangement on an available site.The sponsors never located investors, but it was an educational period.
A growing company desired to relocate its HQ location. JPR analyzed features,
incentives and taxes, real estate options and costs in four cities on the short list , then summarized them for the client to choose,
Richmond, Va. We then worked with community development there to find potential real estate, and to finalize the corporate incentives
For a multi-plant corporation, helped to setup the operation for a maquiladora
operation in Nuevo Laredo. To relieve congestion, relocated operations within the home campus. To expand capacity searched for a community then found property and relocated major operations, later expanded. Texas.
Merger and Acquisition Case Studies; perform manufacturing
due diligence, later integrate operations
Objectives: Ascertain operating conditions both favorable and unfavorable in manufacturing acquisition candidates; later
achieve expected benefits of consolidation.
created an integrated
manufacturing layout for two under-utilized metal working plants, and relocated the Texas plant into the
Pennsylvania facility. Determined usage of equipment, which of multiple pieces to retain, laid out the Pennsylvania plant to
accommodate equipment with good flow and space usage, including process, materials, admin and support people.
manufacturing equipment of an eyewear company before acquisition, later integrated equipment into
a similar business. Texas
JPR assisted a pharmaceutical company to relocate
two manufacturing facilities to similar plants and gain overall productivity. New Jersey and
New Your into Maryland and North Carolina
JPR evaluated manufacturing operations of a
pharmaceutical company before acquisition, then justified and scoped a relocation, then planned for the new upgraded facility necessary. Florida
JPR evaluated an eyewear manufacturing operation for
possible acquisition, and was part of the recommendation not to proceed. Virginia
JPR will objectively and confidentially assist you to increase productivity and
profitability in all aspects of manufacturing,
distribution, service and administrative operations. JPR reinforces your own resources, and brings a high level of experience.
Contact Jack Greene today for a rapid response, at 843-422-1298 or