Power & Lawn Equipment Co. Uses Automation & AVIX Technology for Line Balancing and Schedule Attainment

Facing Tariffs and Capacity Constraints. How This Outdoor Equipment Company Found a Smarter Way to Win

Faced with a complex mix of challenges—including rising tariff costs on components imported from China, surging consumer demand, and limited injection molding capacity—this leading outdoor equipment company struggled with low schedule attainment and escalating operational costs.

Challenge

High tariff costs from China, rising consumer demand and limited injection molding capacity leading to low schedule attainment.

Rising consumer demand and limited injection molding capacity lead to low schedule attainment, with Overall Equipment Effectiveness (OEE) at just 50% and uptime hovering around 60%. The mower assembly line depended heavily on temporary workers, leading to higher labor variability and costs while lowering overall efficiency. At the same time, supply chain disruptions were inflating material costs, and the organization lacked a structured approach to problem-solving and issue resolution—further compounding production inefficiencies.

Solution

We implemented a multi-faceted operational strategy focused on boosting productivity and reducing costs by optimizing existing automation, improving preventive maintenance routines, and shortening changeover times.

The adoption of advanced technologies—including robotic tooling, torque guns, automated feeders, tow motors, and palletizers—helped modernize production. Visual management and key performance indicators (KPIs) were used to track and address losses related to scrap, rework, and minor downtime. The team also introduced AVIX for line balancing technology to streamline staffing and implemented a daily management system that significantly improved the injection molding line’s output. Together, these solutions enabled the company to meet high customer demand while managing costs and maximizing existing capacity.

Results

Smarter operations reduced labor costs by $429K, boosted productivity by 11%, and increased output by 275 units per shift—driving $27.5M in annual sales growth.

The operational improvements delivered significant, measurable gains across the board.

  • By optimizing the production line and leveraging automation, the company reduced labor by 18%, decreasing full-time equivalents (FTEs) from 54 to 44.
  • Workforce reduction, combined with more efficient line balancing, resulted in $429,000 in annual labor savings.
  • Productivity per hour improved by 11%, enabling the team to boost output by 275 units per shift.
  • $27.5 million increase in annual sales, demonstrating how smarter operations can translate into both cost savings and revenue growth.

Topics in this Case Study

Supplier ManagementMaintenance ExcellencePerformance Improvement

At a Glance

Client

Power and lawn equipment company, leader in outdoor power equipment

Results

  • Reduced labor by 18% from 54 FTEs to 44
  • Improved productivity per hour by 11%
  • Achieved $429,000 in annual labor savings by optimizing the line and reducing headcount by 9
  • Increased annual sales by $27.5 million by boosting output by 275 units per shift.
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