Why a small shop hires this instead of a manager
A full-time continuous-improvement manager runs about $100k a year before benefits. Most shops with 10 to 200 people can't justify that for a role they need for weeks, not years — but they still bleed money on scrap, slow changeovers, and layouts nobody has questioned since the shop opened.
I sell the weeks: a diagnostic that finds the waste, then fixed-scope sprints that fix it. You keep every fix, every file, and every number either way.
Signs this is worth a call
You might not need a consultant. But if any of these sound familiar, a diagnostic is probably worth the call: lead times keep slipping and customers are noticing; output has flatlined and the only answer anyone offers is overtime or another hire; scrap and rework are eating margin; the floor is full but nobody can say where the capacity actually went; or you tried lean before and the improvements quietly slid back. The waste is usually in the same eight places: making too much, waiting, moving things too far, doing more work than the customer asked for, holding too much inventory, wasted motion, defects, and ideas from your own operators that nobody ever used.
What the work looks like
1. Process diagnostic
A structured walk of your floor and your files: where material, time, and quality are actually being lost, measured before anything is changed, and written up in priority order. Yours to keep whether or not you hire me for the fixes.
2. Fixed-scope sprints
- Changeover reduction — setups and changeovers, the specialty: getting a cell from one job to the next with less downtime.
- Scrap reduction — find where rejects are born and cut them at the source.
- 5S and visual management — one cell or area, organized so the next operator inherits order, not archaeology.
- Work instructions and SOPs — documentation your operators will actually use, written from the floor.
Each sprint is quoted as a fixed scope after a free intro call. No hourly meter running while you wonder what you're paying for.
Measured results, from real floors
These are results from production work, stated the way they were measured — not rounded up into a sales story:
~1 month
Production time — credited with saving roughly one month of production time, from a single week of Kaizen improvements at a medical-device manufacturer.
7–91 cm
Less material per run across reworked fabric cutting files at a textile laser-cutting operation — about 43 cm on average.
$36.50/yd
The price of one fabric in those files. At that price, the two biggest file savings alone are worth $34.82 and $36.13 every time they run.
300 → 700 mm/s
Cutting speed on one file type, more than doubled — stated as feed rate, because that is what was measured.
≥10%
Scrap reduction across the board after the same round of changes.
Employers are anonymized. No client names, no product details, no proprietary parameters — outcomes only.
Who this is for — and who it isn't
A good fit: any manufacturer with a production floor where waste is hiding — material lost to the file, setups eating the day, scrap nobody has traced to its source. I have worked across a wide variety of production situations, so the fit is the shape of the problem, not one industry.
Not a fit: a shop that wants a guaranteed savings number before anyone looks at the floor, or a redesign of equipment and controls — that's engineering work outside this practice.
How it works
- Free intro call. Your shop, your bottleneck, your timeline. If it's not a fit, I'll say so.
- Diagnostic. Measured waste, prioritized, in writing.
- Sprints. Fixed scope, fixed quote, done on your floor with your operators — so the improvements stick after I leave.
Where I work
Based in Las Vegas, Nevada, traveling to client sites across the United States.
Your floor stays yours
Everything I see and hear in your shop — processes, products, customers, numbers — is confidential. I don't share it, copy it, or reuse it anywhere else. If you have an NDA, I'll sign it before the diagnostic starts.
Start with an intro call
Intro calls are free. Tell me your shop size and your biggest bottleneck, and I'll tell you honestly whether a diagnostic is worth your money.
Spotlight Results is a new practice. No testimonials or client logos yet — just measured work, stated plainly. I won't quote a savings number before I've measured your floor; anyone who does is guessing.