Where I can help.
Engagements range from a one-day assessment to leading a project through commissioning. Each one is scoped to the problem, not to a package, for manufacturers in any industry.
Operational efficiency
Items 1.1 to 1.3Getting more good product out of the plant you already have.
Process optimization
I study the process end to end, measure where throughput, recovery and uptime are being lost, and prioritize the fixes that pay back fastest.
Lean manufacturing
Lean tools applied where they fit: value stream mapping, standard work, visual management and structured problem solving. I am a Lean Sensei International certified Green Belt.
Workforce training and development
Building the skills of operators, trades and supervisors, so the improvements last after I leave.
Industrial automation
Items 2.1 to 2.3Controls designed by someone who has also been accountable for the production numbers.
Control systems
PLC and HMI design, programming, troubleshooting and upgrades, including migration planning for ageing controllers.
Industrial networks
Plant-floor network design and clean-up, so controllers, drives, cameras and business systems communicate reliably.
Machine vision and robotics
Assessing where vision and robotics make sense, specifying the system and integrating it with the existing controls.
Safety and reliability
Items 3.1 to 3.3Protecting people and keeping equipment available.
Functional safety systems
Safety controllers, guarding interlocks and safe-access systems that protect people without tempting them to bypass.
Predictive maintenance systems
Using the data already in the control system, plus targeted sensors, to see failures coming and plan the repair.
Automatic lubrication systems
Specifying and commissioning automatic lubrication, so bearings and chains get the right amount at the right time.
How an engagement goes
Every engagement, in orderThe technology is the easy part. The work is understanding the process and bringing the people along.
Walk the floor
I start in the plant, watching the process and listening to the people who run it.
Find the constraint
Data and observation pin down what is limiting throughput, quality, safety or uptime.
Fix it together
We design the change with operators, maintenance and management, so it belongs to the plant.
Leave it running
I train the team, document the work and confirm the result holds before stepping away.
Tell me about your plant
Replies come from me directlyDescribe what the line is doing and what you want it to do. You will hear back from me directly.