Clear Scope.
Clear Outcomes.
Start with a 2-day assessment. We quantify your per-shift margin leakage, correct the root causes, and install discipline so it doesn't return.
MARGIN RECOVERY FIRST. LEAN DEPLOYMENT SECOND.
Quantify What Margin Leakage Is Costing You Per Shift
Many mid-market manufacturers lose money every shift — they just can't see where it's leaking. In 2 days on your floor, we measure where paid time is not producing output, confirm the constraint, and quantify the loss in per-shift dollars. At the end of Day 2, you get (1) your per-shift exposure, (2) the annualized impact, and (3) a prioritized recovery roadmap. You can execute internally or move to Phase 2.
- Walk the flow end-to-end and mark where work stops, waits, or rework starts
- Time-stamp idle delays — people waiting, machines waiting, material waiting
- Identify the constraint and confirm it with throughput and WIP behavior
- Translate lost time into dollars: labor, overtime, missed output, and expediting cost
- Verify with your labor plan, production targets, downtime logs, and scrap/rework
This is not a "lean report." It's a margin exposure measurement.
Based on observed idle time, downtime, throughput loss, overtime, and material flow friction. Verified with your production + labor data.
Example: 18 operators × 20 minutes/hour of idle time = 6 paid labor hours lost per shift. At $32/hr loaded cost, that's ~$190 per shift in labor alone. The real cost is the throughput you don't produce — which shows up as overtime, missed shipments, expediting, and margin erosion. That's why we measure time loss and constraint output — then convert it to dollars.
- 2 days of floor observation across all active stations
- Per-shift dollar leakage identified and quantified
- Bottlenecks and idle time mapped to specific areas
- Prioritized list of fixes ranked by financial impact
- Executive-ready presentation of findings
- 30–60–90 day recovery roadmap
- Executive-ready slide deck (sample format shown on the call)
- Leakage calculator and assumptions sheet so finance can validate the math
You know exactly what margin leakage is costing you — in dollars, per shift — before spending another dollar.
Best fit: $10M–$40M revenue · 75–200 employees · Tier 2–3 automotive / metal stamping / fabrication
Not a fit: Under $5M revenue · Enterprise with internal CI team · "Just exploring"
These are the same measurement and constraint principles used in high-volume production environments where small inefficiencies compound into major cost. The tools are simple. The discipline is not.
I'm opening two pilot assessments at a reduced rate in exchange for permission to publish an anonymized case study (no company name, no sensitive data). If it's a fit, we'll cover details on the call.
Fix the Bottlenecks. Recover the Margin.
Scope defined in Phase 1 findings
Pricing depends on: number of constraints in scope, shift count, and how many areas we're fixing.
The assessment showed you where the money is going. Now we fix it. We work directly on your floor — balancing labor, stabilizing the constraint, and removing the backup points that reduce throughput. The goal is simple: convert measured leakage into recovered margin within 4–8 weeks. This is hands-on work, not a report. When we leave, the constraint is stabilized and measurable capacity has increased.
- Workload redistributed across stations so no position is idle or overwhelmed
- Backup points and bottlenecks resolved at the source
- Unplanned downtime reduced through root cause correction
- Throughput and units-per-hour improved and tracked
- Labor matched to actual demand across the shift
- Weekly progress updates with before/after metrics
The root causes are fixed. Throughput is up. Your floor runs closer to its actual capacity.
Build the Systems That Keep the Gains.
Most improvements die after the consultant leaves. People revert, standards fade, and the floor slowly returns to the old way. Phase 3 installs the routines, KPIs, and leadership cadence that protect recovered margin without needing us on-site forever. We train your team leads, build your KPI tracking, and set up the daily routines that catch problems before they become losses. You end up with a floor that runs on process — not on one person holding it together.
- Tiered daily management system (Tier 1–3) with escalation rules
- Team lead and supervisor training on standard work and daily accountability
- KPI dashboard built and implemented for your floor
- Daily huddle and escalation routines established
- Standard work built for the top 5–10 critical processes
- Lean Six Sigma principles embedded at the supervisor level
- Monthly reviews to measure and protect recovered margin
Your team can identify and fix problems without you. The margin you recovered stays recovered.
$2,000–$6,000 Can Leak Per Shift
Without Being Visible.
Schedule a 20-minute call to see if a 2-day assessment makes sense for your operation.
We'll estimate exposure from your labor, output, and downtime data — then confirm it on the floor.
No pressure. We'll look at the numbers together.