Your factory and warehouse problems, solved.

In power system cabinets, connections and small devices were coming loose during or after final testing.

Traced the problem back to an earlier assembly stage: large bolts were checked for tightness, but smaller screws and connections had no standard, so they ended up too tight or too loose. Worked with design and manufacturing to write a tightening guide for small devices and connections.

Lines building custom data center switch and power control units: 21% of kits reached the line with errors, and cycle times ran long.

Traced where kit errors started and fixed the causes, working with the final assembly and test team.

A new warehouse had to be designed from the ground up for a $1B+ plant.

Designed the layout and storage racks and tested them in a computer simulation, alongside new inventory software and a 90-day just-in-time stock plan.

Operators had long idle periods, and it was unclear whether job scheduling matched the real workload.

Watched how work was really done, recording idle time, walking and movement, and time spent on productive versus non-productive work. Used this to rework the job schedule and fill the idle time.

Microchip component production in the Birck cleanroom gave output quality that varied unpredictably from batch to batch.

Tracked every process step with statistics and found two causes: a wrong machine setting and a change in raw material batch.

Schweitzer Engineering Laboratories, launching a new connector line, needed an assembly cell designed within a $75,000 budget.

Led a five-engineer team through the cell design and costed three levels of automation, so leadership could choose the trade-off between investment and output.