OUTCOME · CAPACITY

Get more out of the lines you already have.

We typically lift throughput and yield by 10–15%+ on the lines we touch — usually before a single piece of new equipment is ordered. The constraint isn't always where the spreadsheet says it is.

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── WHEN THIS IS FOR YOU ──

01

Demand is up. Capex is tight.

You need more units off existing assets before the next budget cycle. Buying your way out isn't on the table.

02

The line runs — but micro-stops eat real hours.

Short-duration stoppages, alarm noise, manual resets. They don't show up in monthly reports but they're costing you a shift a week.

03

Yield bounces and no one knows why.

Some weeks you ship clean. Some weeks scrap is up 4 points. The data exists somewhere, but no one can tell you what changed.

04

Operators are firefighting, not improving.

Recovery has crowded out prevention. Your best people are the ones putting out fires — which means they're not the ones eliminating them.

── WHAT YOU GET ──

Outcomes, not deliverables.

01 · OUTCOME

10–15%+ throughput uplift

Sustained gain on the targeted lines, measured against an honest baseline — not a cherry-picked week.

02 · OUTCOME

Yield improvement

Visible, measured, and sustained. We don't ship a one-off pop and call it done.

03 · OUTCOME

Constraint clarity

You'll know — with data, not opinions — what's actually limiting your output today and what's coming for you next.

04 · OUTCOME

Cross-shift consistency

Standard work, daily-management rituals, and visibility that closes the gap between A-shift and the back shift.

05 · OUTCOME

A repeatable model

What worked on the first line gets packaged for the next four. The improvement isn't a hero project — it's a method.

06 · OUTCOME

An honest read on what's next

If we hit the cap on existing assets, we'll tell you straight when the next capex is justified — and why.

── HOW WE DELIVER IT ──

Capacity gains come from one of four routes — sometimes more than one. We pick what fits the constraint and the timeline you have.

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

2×

Beast assembly throughput, no major capex

── FAQ ──

How quickly can we expect to see throughput move?
Most engagements show a measurable lift inside 8–12 weeks on the targeted line. Faster is possible when the constraint is mostly informational (visibility / standard work). Slower when the constraint is structural (layout, equipment).
Do we have to commit to a multi-year transformation?
No. A common entry point is a Rapid Impact engagement on a single line — 4–8 weeks, fixed scope, fixed fee. If it works, scaling is an option, not a contractual obligation.
What if we already tried Lean and it didn't stick?
We hear this often. Most failed Lean rollouts didn't fail at the tools — they failed at adoption and at the operating ritual. We rebuild around how the line actually runs, with the operators in the room.
How do you measure honestly when our baseline is messy?
Step one is usually instrumentation: closing the gaps in baseline data so the before-and-after is defensible. We don't claim wins against a baseline you can't trust.
Will this require new software 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 metric, not a category.

Want more out of the assets you have?

30 minutes, working session. Bring the line that's capping output and we'll walk you through how we'd attack it.

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