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How It Works
How We Help You Cut Setup Time and Standardize Processes
A practical, shop-floor approach that fits how job shops actually operate.
We’re not going to hand you a binder full of recommendations and walk away. We work alongside your team, implement changes on the floor, and make sure improvements stick.
Here’s how it works.
Step 1: We Walk Your Shop and Find What's Costing You Time
Every shop is different. We start by understanding how you actually operate—not how a textbook says you should.
What Happens:
- We spend time on your shop floor observing setups, talking to operators, and reviewing your current processes
- We analyze setup time across different machines and job types
- We identify specific time waste: tool hunting, missing documentation, unclear instructions, fixturing delays
- We review your workflow from job release to shipping
- We talk to your team—operators, supervisors, and management—to understand what's working and what's broken
What You Get:
A written assessment that identifies high-impact improvement opportunities, quantifies potential time savings, and prioritizes next steps.
Timeline:
Typically 1-2 days on-site, followed by a detailed debrief.
Cost:
Free initial assessment for qualified shops.
Step 2: We Build a Roadmap Based on What Will Move the Needle
No cookie-cutter solutions. We design an improvement plan specific to your shop’s constraints, equipment, and priorities.
What Happens:
- We identify the highest-impact jobs, machines, or processes to tackle first
- We develop a phased implementation plan that fits your production schedule
- We define clear metrics: setup time reduction, operator variation, schedule adherence
- We outline resource requirements and timeline
- We get buy-in from your team before we start
What You Get:
A practical roadmap with clear deliverables, timelines, and expected results.
Timeline:
1 week to develop and present the plan.
Step 3: We Work On Your Shop Floor to Implement Improvements
This is where the work happens. We’re not consultants in a conference room—we’re on the floor with your operators making changes that stick.
What Happens:
- We standardize tooling setups, fixtures, and pre-staging routines
- We document processes alongside your senior machinists
- We create setup sheets, work instructions, and tooling lists with photos and annotations
- We digitize legacy documentation and build searchable job libraries
- We train operators on new procedures in real time during actual production
- We troubleshoot issues as they come up and adjust methods based on what works
What You Get:
Documented, standardized processes that reduce setup time and eliminate variation. Operators who know how to follow—and improve—the new methods.
Timeline:
Varies by scope. Typical engagements run 4-12 weeks with on-site time scheduled around your production.
Step 4: You Own the Improvements
We don’t want you dependent on us. The goal is to build capability in your team so you can keep improving after we’re gone.
What Happens:
- We train your supervisors and lead machinists to sustain gains and coach operators
- We establish metrics and review routines so you can track performance
- We create a continuous improvement process so small issues get solved before they become big problems
- We document everything so your team has a reference library
- We do a final walkthrough to confirm improvements are holding
What You Get:
A self-sufficient team, documented processes, and the tools to keep getting better.
Timeline:
Final 1-2 weeks of the engagement, plus optional follow-up check-ins at 30 and 90 days.
Why This Works When Other Consulting Projects Don't
Most consulting projects fail because they ignore how shops actually operate. We don't.
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01
We've Done the Job
We're not career consultants. We've run CNC machines, set up 4-jaw chucks, troubleshot offsets at 2 AM, and dealt with the same frustrations you have. We speak your language because we've lived your problems.
02
We Work On the Floor
We don't hand you a PowerPoint and leave. We implement changes alongside your team during live production. If it doesn't work in the real world, we adjust until it does.
03
We Focus on Practical Wins
No buzzwords. No theory. No process maps that look impressive but don't reduce setup time. We focus on measurable improvements that show up in your schedule and your bottom line.
04
We Make You Self-Sufficient
Our goal is to work ourselves out of a job. We train your team to sustain and expand improvements so you're not calling us every time something needs tweaking.