Consulting Solutions for Better Manufacturing Workflows

Diagnose and Prioritize What Slows Your Flow

We guide teams through value stream mapping sessions that expose wait times, rework loops, and approval delays. A Midwest metal fabricator discovered 38% of lead time was idle, unlocking simple sequencing changes that improved delivery without adding headcount.

Lean, Six Sigma, and TOC: Stronger Together

We redesign layouts, material presentation, and replenishment to reduce unnecessary movement and waiting. A precision assembler reduced walk distance by 62% using point-of-use kits and flow racks, cutting changeover headaches and stabilizing takt adherence across shifts.

Digital Enablement: MES, IIoT, and Analytics That Matter

We implement MES for live status, digital work instructions, and traceability, paired with e-kanban to smooth replenishment. Teams gain a single source of truth, cutting paper chases and improving schedule adherence without drowning in dashboards.

People and Change: Equip the Workforce to Own the Flow

We create Kaizen circles with clear problem statements, lightweight experiments, and rapid validation. A food manufacturer captured 147 ideas in two months; 61 were implemented, eliminating nuisance adjustments and boosting morale alongside throughput.

People and Change: Equip the Workforce to Own the Flow

We develop standard work, visual aids, and skills matrices so anyone can perform critical tasks consistently. Cross-training reduced overtime reliance for a tier-one supplier, while clearer standards cut start-up scrap during shift handovers by more than half.

People and Change: Equip the Workforce to Own the Flow

We install leadership routines—daily gemba walks, purposeful coaching, and crisp tiered meetings. Issues surface early, and accountability feels supportive, not punitive. Leaders spend more time improving systems and less time chasing yesterday’s fires.

Quality by Design: Right-First-Time as a Workflow

We facilitate practical PFMEAs that show real failure modes and link to control plans operators trust. By tying checks to natural process points, a stamping plant reduced missed detections and eliminated recurring customer complaints.

Quality by Design: Right-First-Time as a Workflow

We shift checks upstream with in-line gauges and SPC alerts. When trends drift, teams correct immediately. A wire harness line cut escapes by 70%, and rework benches went from overwhelmed to occasionally bored.

Planning, Scheduling, and Supply Synchronization

We mature S&OP from calendar ritual to decision forum. Clear constraints, scenario analysis, and agreed trade-offs stop last-minute chaos and improve on-time delivery without inflated safety stocks that quietly erode margin.

We stabilize inbound flow with supplier scorecards, shared forecasts, and pull signals. One electronics client halved shortages after kanban went live with two key suppliers, reducing expedites and freeing planners to optimize, not chase.

We deploy finite schedulers and smart sequencing rules that consider setup families and constraints. A coatings shop increased throughput by batching colors scientifically, cutting washout time while meeting customer due dates more reliably.