Proven Success Across Manufacturing Sectors
Explore how our targeted strategies have transformed operations, boosted efficiency, and delivered measurable results for clients in automotive, aerospace, medical, and industrial manufacturing.
examples of projects
DOE on a hydraulic forge press to support production of lightweight aluminum truck wheel
Objective: Achieve the desired grain structure to support weight reduction in class 8 aluminum truck wheel; solve for no negative impact on operational performance, namely forge die tool life.
To start, through a PFMEA style analysis, it was necessary to understand top key process input parameters. Through a well-planned Design of Experiments (DOE) approach, the team was able to identify the top control parameters influencing the manufacturing process. These findings were used to successfully optimize the grain structure without significant press or heat treatment performance issues. Additionally, leveraging this refined methodology, we later achieved an impressive milestone by reducing the weight of the aluminum wheel a second time, demonstrating the versatility and effectiveness of our optimized process. This led to an improved NA market share position.
tooling cost improvement on an automotive part application.
Objective: Reduce the high cost associated with tooling used for machining the ID hole in a transmission shaft. Through a cross functional CI process, the team used a simple pareto approach to identify top tooling cost driver from the Cost Per Unit (CPU) profile. Once identified, the team initially pursued alternatives for this expensive tool. During their investigation, they discovered a process modification enabling extended life of the tool by an impressive factor. Following this discovery, trials were conducted to validate the effectiveness of the proposed process change, which ultimately received approval from the customer. The financial impact of these efforts resulted in a significant savings of $0.18 CPU, a noteworthy achievement, especially considering the demand for production was 14,000 units per week. This accomplishment not only underscores the importance of driving CI cost reduction but also highlights the potential for efficiency gains within the manufacturing process.
inventory lead time improvement.
Objective: The primary area of focus was raw material management. The VSM inventory lead time for the plant was 18 days, with raw material being 5 days. The supplier was located approximately 2 hours away from the facility. We collaborated with the supplier to implement a point-of-use process to be driven by plant driver scanning the materials upon retrieval from dock. This scan served as an immediate notification to the vendor, allowing for timely replenishment. The Service Level Agreement (SLA) was structured around 4-hour increments, ensuring that our supply chain remained agile and responsive. As a result of these efforts, we were able to reduce the raw material lead time to 0.5 days, significantly enhancing inventory efficiency. Additionally, during the winter months, the facility took proactive measures by maintaining two trailers of consignment safety stock, which acted as a buffer to protect against potential weather-related disruptions and ensure uninterrupted operations.
high stakes throughput improvement.
Objective: Improve throughput on a new product launch to address a severe past due condition. Through careful analysis, we confirmed the performance of the constraint operation was the problem. At current program volumes, constraint OEE was inadequate to meet demand, mainly due to available time. Availability before OT was 80 hours per week on constraint equipment. OT was voluntary and inconsistent at best. As an immediate countermeasure, the plant installed a dedicated constraint team, expanding availability before OT to 120 hours per week, with the flexibility to go to 144 hours with OT. Throughout this process, we made incremental improvements to performance and quality, the other two critical components of Overall Equipment Effectiveness (OEE). Thanks to these efforts, we managed to successfully clear the backlog in just six weeks, demonstrating the effectiveness of the approach to managing constraints while prioritizing quality and performance.
global CI program.
Objective: Successfully implement a Global Continuous Improvement (CI) program. Over the course of six months, we developed and launched a comprehensive cloud-based CI program that was effectively rolled out to 15 manufacturing plants located around the world. The guiding principle for the design of this program was to maintain simplicity while ensuring effectiveness, anchored by a disciplined review cadence that kept all teams aligned and focused. We maximized our efficiencies by utilizing resources drawn from our existing operations, allowing us to streamline processes without significant additional investment. At the core of our strategy was a relentless commitment to identifying and eliminating the seven types of waste within the enterprise, which not only enhanced operational efficiency but also fostered a culture of continuous improvement. As a significant indicator of success, it is worth noting that EBITDA met the full year business plan while sales were down 10% overall. This was largely attributable to the positive impact of the CI program.
...And many many more.
28%
Average Cost Reduction
35%
Increase in Production Capacity
Proven Results Across Manufacturing Sectors
Through targeted strategies, we have enhanced free cash flow, optimized asset utilization, and resolved complex operational challenges for diverse manufacturing clients.
Engage
Collaborative Partnership
We begin by working closely with your leadership and teams to understand your unique challenges and operational goals, ensuring alignment from the start.
Analyze
Insight
Through detailed data review and on-site assessments, we identify bottlenecks and inefficiencies that limit your manufacturing performance.
Implement
Action-Oriented Solutions
Our hands-on approach focuses on practical changes that unlock capacity, improve cash flow, and enhance quality without disrupting your operations.
Sustain
We equip your teams with tools and strategies to maintain improvements, fostering continuous operational excellence beyond our engagement.
Manufacturing
Your Questions Answered
What industries do you specialize in?
Our expertise spans precision machining, automotive OEM, commercial transportation, medical, industrial, and aerospace manufacturing sectors. We tailor solutions to the unique challenges of each industry.How do you approach operational improvement projects?
We combine hands-on leadership experience with data-driven analysis to identify constraints, optimize processes, and implement sustainable changes that improve capacity and cash flow.What results can clients expect?
Clients typically see measurable improvements in operational efficiency, cost reduction without quality loss, enhanced free cash flow, and stronger negotiation outcomes with suppliers and labor.How involved will your team be during the engagement?
We work closely with your leadership and frontline teams, providing hands-on support and strategic guidance throughout the project to ensure alignment and effective execution.What makes Operations Consulting different?
With over 30 years of direct manufacturing leadership, we bridge strategy and execution, focusing on real-world solutions that address systemic issues and deliver lasting operational excellence.