Industrial Engineering Consulting

Most plants already know something is wrong. What they usually lack is the measurement that turns a suspicion into a decision you can defend in front of the people who control the budget.

I spent seven years doing this work on the floor before I started building software for it. That order matters. A capacity model is only worth as much as the assumptions underneath it, and knowing which assumptions quietly break is not something you get from a template.

Where this usually starts

You are being asked a question that the current numbers cannot answer. How much more can this line take before we add a shift. Why does this cell hit standard and that one never does. Where is the labor cost actually going. The data exists, scattered across production records, engineering studies, and spreadsheets that only one person knows how to update.

How I work through it

First the process gets measured properly: the real cycle, the real constraint, the real variation, not the version that was documented once and never revisited. Then the analysis, using the standard industrial engineering toolkit, time and motion study, capacity modelling, standard versus actual variance, labor cost breakdown.

Then the part most consultants skip. The analysis gets built into something that keeps running after I leave. A study tells you what was true in March. A system tells you what is true today, which is what stops the same drift from quietly returning next year.

What you get

A written answer to the question you asked, the working underneath it so you can check it rather than take my word for it, and where it makes sense, a tool that keeps the measurement alive. If the honest answer is that your process needs changing rather than software, I will tell you that, and it costs you nothing.

Working together

I take these engagements on a freelance, trial, or volunteer basis, and I am happy to start with a single question rather than a full assessment. Small and mid-sized manufacturers are the focus, because they carry the most manual analysis and get the least attention from large consultancies.