“We are integrating the Kepner Tregoe process into other company standard systems. Employee involvement coupled with the Analytic Trouble Shooting approach is helping the company reach our ever expanding goals.”

— Jim Phillips, Plant Manager, GAF Materials Corporation

GAF Materials Corporation reviews savings from implementing Kepner-Tregoe’s business process improvement strategies.  By determining the root cause swiftly and using a common language to identify as well as solve problems, GAF Materials Corporation has cut conversions costs by $5.5 million in two years.

CLIENT: GAF Materials Corporation (gaf.com) is North America’s largest roofing materials manufacturer.

CHALLENGE: To cut costs and position the organization to meet expanding goals.

SOLUTION: Since the implementation of the Kepner-Tregoe Analytic Trouble Shooting® process at GAF’s Michigan City manufacturing plant, the facility has realized a $5.5 million reduction in conversion costs over a two-year period. All salaried employees as well as key hourly employees have been involved in implementing the approach.

RESULTS: The program helped GAF employees use a rational thought process to solve problems and provided a standard vocabulary which improved communications throughout the plant. This allowed GAF to identify key process variables and implement a measurement system to determine root cause faster and more effectively. Other GAF Materials Corporation plants have implemented Kepner-Tregoe methodology with similar results.