Enhancing Manufacturing Efficiency with Strategic Consulting
Diagnose Before You Prescribe: Finding the True Constraints
Map the Value Stream, Not Opinions
We start with value stream mapping and time observation, replacing speculation with flow facts. Seeing queue times, rework loops, and handoffs on one page sparks alignment and action.
Establish a Ruthless Baseline
OEE, first-pass yield, changeover time, and schedule adherence form your unblinking baseline. When everyone trusts the numbers, improvement debates shift from personal preferences to objective priorities.
Prioritize by Economic Impact
A weighted impact model links constraints to dollars: margin leakage, late penalties, overtime, and scrap. The result is a sequenced improvement backlog that leadership funds without hesitation.
Strategy to Shop Floor: Alignment That Actually Sticks
Translate Strategy into Measurable Shop-Floor Targets
We convert strategic objectives into line-level KPIs, tiered huddles, and owner dashboards. Operators see how today’s setup optimization advances quarterly throughput commitments and strengthens customer promises.
Cadence of Accountability
Tiered daily meetings and weekly performance reviews create rhythm. Issues escalate within hours, not months, with clear owners, timestamps, and recovery plans that protect both flow and morale.
Visual Management That Drives Behavior
Scoreboards, andons, and standard work visuals reduce ambiguity. When abnormal conditions are instantly visible, teams intervene early, sustain gains, and celebrate progress that customers and finance can feel.
Lean Meets Industry 4.0: Technology with Purpose
We automate where it matters most: the bottleneck. Whether cobots or smarter fixtures, constraint-focused automation multiplies capacity and prevents expensive, dispersed technology that never changes overall throughput.
Lean Meets Industry 4.0: Technology with Purpose
Right-sized IIoT captures cycle times, micro-stops, and condition data. Operators receive clear alerts, planners get reliable lead times, and leaders finally trust the numbers driving capital and staffing decisions.
We coach small, daily experiments owned by operators. When the person closest to the work leads improvement, ideas multiply, resistance fades, and results outpace top-down initiatives every time.
People-Centered Change: Engaging the Frontline
Targeted coaching builds problem-solving muscles: A3 thinking, SMED, 5S, and root cause analysis. Leaders learn to ask better questions, not provide quicker answers, raising the organization’s long-term capacity.
People-Centered Change: Engaging the Frontline
Resilient Flow Beyond the Factory: Supply and Scheduling
We set dynamic buffers using demand variability, lead times, and service goals. The result is fewer expedites, steadier lines, and cash released from overbuilt safety stock across sites.
Finite-capacity scheduling and realistic changeover windows reduce chaos. When schedules reflect actual constraints, on-time delivery rises and overtime stops masquerading as a sustainable strategy for growth.
We co-develop supplier scorecards, kanban loops, and shared forecasts. Joint improvement unlocks better yields and shorter lead times, strengthening resilience without simply pushing costs upstream.
Proof in Practice: A Story from the Line
OEE averaged 58%, changeovers stretched past ninety minutes, and three part families missed weekly ship dates. Operators felt blamed, planners felt helpless, and customers warned of shifting volume.
