Before.
After.

The Problem

A Tier-2 supplier kept refusing new orders — every line was 'full'. Yet EBITDA was shrinking and the OEM was threatening dual-sourcing over delivery slips.

The Investigation

Four weeks of floor-level OEE study revealed the truth: machines were occupied, not productive. True OEE was 52%. Changeovers took 3× the standard, and one bottleneck press dictated the entire plant's rhythm.

The Solution

SMED on the bottleneck press, rebalanced lines around actual demand mix, TPM on the four critical machines, and a daily performance board reviewed at 9:00 AM sharp.

The Problem

A corrugated box maker quoted healthy margins on every job — and still closed most months near break-even. Nobody could explain where the margin went.

The Investigation

Clean sheet costing across the top 40 SKUs exposed it: paper yield losses of 9%, unbilled design changes, energy costs allocated nowhere, and three customers who were quietly loss-making at any volume.

The Solution

Re-priced the loss-making accounts, built a live yield dashboard on every corrugator shift, renegotiated kraft paper supply against a should-cost model, and tied supervisor incentives to waste percentage.

The Problem

A switchgear manufacturer faced the same field-failure complaint for the third year running. Each time: a report, an apology, a corrective action. Each time it returned.

The Investigation

Root cause analysis traced the failure through assembly to an incoming component whose supplier had changed material grade — twice — without notification. Incoming inspection sampled the wrong parameter entirely.

The Solution

Supplier quality agreements with change-control clauses, incoming inspection redesigned around failure modes (FMEA-driven), and a first-pass-yield board at every assembly cell.

The Problem

A machine builder with genuinely superior equipment grew only through referrals. Two large relationships drove 70% of revenue — and one of them was consolidating vendors.

The Investigation

The demand audit was blunt: no digital footprint, no funnel, no CRM, exhibition leads dying in inboxes. Meanwhile competitors with weaker machines ranked first on every search that mattered.

The Solution

Industrial brand rebuild, technical content engine, LinkedIn + search campaigns aimed at plant heads, CRM with a weekly funnel review, and a dealer program for two new regions.