Frontline process improvement for small shops

Frontline Process Improvement Specialist.
I find the savings on the floor, not in a slide deck.

You don't need a full-time improvement manager. You need the expertise for a few weeks — from someone who has actually run the machines.

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.

What a diagnostic gives you

Measured on your floor, before anything is changed

  • Where material is lost
  • Where time is lost
  • Where quality is lost
  • Fixes, in priority order, in writing

The report is yours to keep, whether or not you hire me for the fixes.

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
  • 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, measured before anything is changed. You get it in writing, in priority order: where material, time, and quality are being lost, what each item is worth in your own numbers, and which fixes to do first.

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

Case study: a single week of Kaizen improvements at a medical-device manufacturer. Saved a month of operator time annually.

7–91 cm

Case study: cutting files at a textile laser-cutting operation. About 20 production cutting files reworked; on the 10 paired fabric files measured, each run now uses 7 to 91 centimeters less material, about 43 centimeters 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

One file type's cutting speed, 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.

Operations are anonymized. No company names, no product details, no proprietary parameters — outcomes only.

Who this is for

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.

Pricing

Straightforward, on purpose. Fixed scope, not hourly. Every engagement starts with a diagnostic.

Diagnostic

$400–$600
one time
  • A structured walk of your floor and your files
  • Where material, time, and quality are actually being lost, measured before anything is changed
  • Written up in priority order
  • Yours to keep whether or not you hire me for the fixes
Request an intro call

Medium — diagnostic + sprint series

~$4,000
a line or department · typically about three months
  • Everything in the diagnostic
  • Several linked fixes worked in sequence
  • Fixed scope, fixed quote
Request an intro call

Deep — diagnostic + a multi-area program — is quoted per engagement. Duration is set per engagement, once the diagnostic shows the scope warrants it.

How it works

Three steps.

1

Free intro call

Your shop, your bottleneck, your timeline. If it's not a fit, I'll say so.

2

Diagnostic

Measured waste, prioritized, in writing.

3

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 shop floors 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.

Request an intro call