Real Manufacturing Problems — Solved with Practical Engineering

I help manufacturers fix production issues that impact cost, delivery, quality, and reliability – by identifying the root cause and implementing solutions that actually work on the production floor.

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Real Problems. Measurable Results.

These are real production challenges solved in demanding environments—where downtime, cost, and performance matter.

CASE STUDY 1

Solved a 35-Year Assembly Problem

Problem

A long-standing assembly issue limited first-pass yield to ~80% and caused failures downstream. Multiple attempts over 35 years had failed.

Action

Led a focused root cause investigation across design, process, and performance data, then implemented targeted design and process improvements.

Result

  • First-pass yield improved from 80% to 100%
  • Test performance increased by 27%
  • Variation reduced by 74%
  • Downstream failures eliminated

CASE STUDY 2

Prevented a Stop-Ship Before It Happened

Problem

A supplier change introduced a defect that threatened production shipments.

Action

Coordinated across engineering, suppliers, and program teams to identify the issue and implement corrective actions under tight timelines.

Result

  • Prevented a production stop-ship
  • Protected delivery commitments
  • Avoided additional cost impact

CASE STUDY 3

Reduced Cost by 65% Through Design Simplification

Problem

A complex design increased cost, lead time, and manufacturing difficulty.

Action

Redesigned the system to simplify components and improve manufacturability.

Result

  • Component count reduced by 28%
  • Cost reduced by 65%
  • Build efficiency significantly improved

CASE STUDY 4

Cut Equipment Transfer Time from 4 Hours to 15 Minutes

Problem

Large equipment movement created a major production bottleneck.

Action

Designed and implemented custom transport carts capable of moving 200,000 lb machines without floor rails.

Result

  • Transfer time reduced from 4 hours to 15 minutes
  • Production flow improved
  • Downtime reduced

CASE STUDY 5

Improved Yield and Reduced Defects with Better Tooling

Problem

Existing fixtures caused inconsistencies, leading to defects and rework.

Action

Designed new tooling using FMEA, lifecycle cost analysis, and shop-floor feedback.

Result

  • First-pass yield improved
  • Defects and rework reduced
  • Process repeatability increased

CASE STUDY 6

Eliminated Recurring Equipment Failures

Problem

Failures were repeatedly addressed without solving the root cause.

Action

Performed root cause analysis and implemented design and process improvements.

Result

  • Recurring failures eliminated
  • Reliability improved
  • Field issues reduced

CASE STUDY 7

Improved Program Execution Under Cost & Schedule Pressure

Problem

Programs required tighter coordination to meet cost, schedule, and performance goals.

Action

Managed Control Accounts and improved reporting, forecasting, and cross-team coordination.

Result

  • Better visibility into program performance
  • Faster decision-making
  • Improved alignment across teams

Where I Can Help

  • Fixture design and tooling improvements
  • Production bottlenecks
  • Automation reliability issues
  • Root cause failure analysis
  • Cost reduction and design simplification
  • Design for manufacturability (DFM)
  • Program and production performance

Have a Production Problem Right Now?

If something in your process isn’t working—whether it’s quality, cost, throughput, or reliability—I can help you identify the issue and fix it.

Contact Me