OUTCOME · WASTE ELIMINATION

Find the loss. Remove the loss. Don't do it twice.

Chronic micro-stops, scrap, and speed loss don't show up in monthly reports because they hide in the seconds. We instrument for the seconds, attack the loss in the order it costs you the most, and design the recurrence out.

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── WHEN THIS IS FOR YOU ──

01

Daily losses you can't pin down.

Output is short again this month. Nobody can tell you where it went. The historian shrugs, the operators shrug, and the variance walks.

02

A scrap pattern that shifts every week.

First-pass yield drifts. Root cause feels like a moving target. The corrective actions don't seem to correct.

03

Repeated manual resets — no clear root cause.

Operators know the recovery dance better than the manual. The system gets restarted; the underlying condition never gets retired.

04

Improvement initiatives don't stick.

Kaizen events ran. The before/after looked great. Six months later the gain is gone and nobody noticed when.

── WHAT YOU GET ──

Outcomes, not deliverables.

01 · OUTCOME

Chronic loss inventory

An honest, instrumented breakdown of where output is actually leaking — by minute, by code, by line, by shift.

02 · OUTCOME

A loss-by-loss attack plan

Top contributors ranked by cost and tractability. Order of attack written down, with owners and dates.

03 · OUTCOME

Stoppage and scrap reduction

Real, measured reduction on the targeted loss codes — not just on the headline KPI. Visible at the line, in the daily-management ritual.

04 · OUTCOME

Operator-led improvement

The people closest to the work running the change. Outside facilitation; floor authority. The pattern that turned Bandit's line around.

05 · OUTCOME

Standard work that holds

Documented, trained, and tied to the daily-management ritual so the gain doesn't quietly walk back out three months later.

06 · OUTCOME

A method, not a one-shot

What worked on the targeted line gets packaged so the next four lines don't need a hero project to get the same result.

── HOW WE DELIVER IT ──

Eliminating chronic loss is part diagnosis, part instrumentation, part operating rhythm. We blend modes to fit how the loss actually behaves — and to make sure the fix outlasts the engagement.

STRATEGY & OPERATIONS

Stop chasing buzzwords. Start solving real problems.

When the question is what to do, in what order, with what budget, and to what end. We translate operational ambition into a sequenced, fundable plan that survives contact with the shop floor.

  1. 01 · LISTENTwo weeks on the floor, in the data, and with leadership. We earn the right to make recommendations.
  2. 02 · FRAMEMap the constraints — physical, informational, organizational — and surface the trade-offs.
  3. 03 · SEQUENCERank initiatives by leverage, cost, and risk. Plan written in your team's language, not ours.
  4. 04 · SHIPFirst initiative goes live. Success is measured on the line, not at the steering committee.
DIGITAL INTEGRATION

Everything between the PLC and the P&L.

OT/IT integration, MES, historians, and the connective tissue that turns shop-floor signals into decisions on the floor and numbers in the boardroom.

  1. 01 · DISCOVERMap systems, signals, and decision points. Where is data created? Where does it need to go? Where does it get lost?
  2. 02 · ARCHITECTDesign the integration layer around your use cases — not a vendor's reference diagram. Standards where helpful, pragmatism where required.
  3. 03 · BUILDConnect equipment, configure platforms, write the bespoke pieces. Working in your environment, with your team alongside.
  4. 04 · OPERATEHand off with documentation, training, and a sustainment plan so the system stays a system that runs.
RAPID IMPACT · RIOT KIT

Weeks, not quarters.

Productized engagement built for ops leaders who want a focused, measurable win on a real line — before signing up for a multi-year transformation. Narrow scope. Fixed timeline. Outcome you can see from the floor.

  1. 01 · SCOPEHalf-day session. We pick the line, the constraint, the metric, and the win condition. In writing, before we start.
  2. 02 · INSTRUMENTBaseline data. Whatever's missing to measure honestly, we add — working from your existing systems where possible.
  3. 03 · INTERVENEThe actual change: control tweak, dashboard, integration, operating ritual. Whatever the constraint demands.
  4. 04 · REPORTBefore-and-after on the agreed metric. Honest read. Recommendation on what to scale, what to leave, what to retire.
LIFECYCLE

The system you bought last year should still be earning.

Adoption, training, and sustainment so the platform you funded keeps shipping value. Most manufacturing software dies of neglect, not bad design — we keep yours alive.

  1. 01 · ASSESSAudit the system, the team, and the operating rituals. Where is value leaking? What broke after go-live?
  2. 02 · STABILIZEFix what's broken, retire what isn't earning, retrain what wasn't learned. Get to a clean baseline.
  3. 03 · EMBEDMake the system part of the daily-management ritual. Operators, supervisors, and ops leadership all see themselves in it.
  4. 04 · EXTENDSmall, scoped enhancements every quarter — guided by what's actually moving the metric, not by feature backlog.
CASE STUDY · BANDIT INDUSTRIES
“I have never seen a company move so quickly before on changing the organization, lining up participants, and getting buy-in.”
— Ryan Cahalane, Founding Partner & CEO, Axiom
READ THE FULL CASE ▶
OUTCOME

47 → 41 mi

Per-Beast parts travel reduced 12% — operator-led, no major capex

── FAQ ──

How is this different from a Lean / Six Sigma engagement?
We use the tools where they fit. The difference is the operating layer underneath: instrumented baselines so the win is defensible, an operator-led team that owns the change, and a daily-management ritual that protects the gain after we leave.
What if our biggest loss is something we can't measure today?
Then step one is closing that gap. We instrument first, attack second. Claiming a reduction against a baseline you can't trust is how Lean programs lose credibility.
Will this require new tooling or platforms?
Sometimes. Often the gain comes from using what's already on the floor more deliberately. When new tooling is the right answer, we'll say so — and tie the spend to a specific loss, not a category.
How do you keep the gain from walking back out?
Standard work, training that sticks, daily-management rituals operators actually run, and quarterly check-ins on the metric. Most failed Lean rollouts didn't fail at the tools — they failed at the rhythm.
Can you start on a single line?
Yes — and we usually recommend it. A focused 4–8 week engagement on one line is the lowest-risk way to prove the model before scaling.

Ready to attack the loss that won't go away?

30 minutes, working session. Bring the chronic loss that's been on your list and we'll walk you through how we'd take it down.

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