Case studies
Results from shops like yours
Three recent projects, shared with permission from the owners.
Cabinet shop, 24 people
Lead time from 9 weeks to 5
Jobs waited days between stations because the schedule was built around full batches. We halved batch sizes, set a daily start list and moved the edge bander next to the panel saw.
Result: Quoted lead time fell from 9 weeks to 5 in four months, with no new hires.
Chair maker, 41 people
Rework down 38 percent
One in five chairs came back from finishing with sanding defects. We added a light table check at sanding and trained two leads to coach the rest.
Result: Rework fell 38 percent in ten weeks and the finish line stopped working Saturdays.
Outdoor furniture, 60 people
On-time shipments from 71 to 94 percent
Spring orders shipped late because the plan ignored seasonal demand. We built a weekly capacity plan in a spreadsheet the owner runs himself.
Result: On-time shipments rose from 71 to 94 percent over one season.
Want results like these?
Most projects start with a two-day shop floor review.