If your plant runs on heroics, you’re paying for it in overtime, rework, missed ship dates, and leadership time spent chasing updates. DECG helps manufacturing teams map the real production flow, find the constraint, quantify the cost, and deliver an execution-ready Efficiency Blueprint your team can implement with confidence.
Common symptoms: WIP piles • expedite culture • “we’re waiting on…” • scrap and rework loops • schedule whiplash • tribal-knowledge SOPs
Related topics: manufacturing process improvement, production bottleneck analysis, rework reduction, throughput improvement, standard work.
Manufacturing is a chain of dependencies. When one link slips, the whole system compensates with overtime, expediting, and “workarounds” that become permanent. We help you replace that chaos with clarity.
We don’t start with tools. We start with the work: how parts move, how decisions get made, and where time and quality leak out of the system.
DECG works with manufacturing leaders and frontline teams to uncover bottlenecks, rework loops, and handoff friction that slow production. The goal is not to “optimize everything.” The goal is to identify the few constraints that create the majority of delay, cost, and frustration.
You’ll get a clear picture of current state (not the version everyone wishes was true), and a prioritized plan that balances throughput, quality, labor effort, and customer delivery commitments. Small improvements create real change when they hit the right leverage points. For manufacturers who also manage distribution operations, coordinating improvements with our distribution workflow consulting ensures production output aligns with warehouse capacity.
If your team says “we just need more people,” there’s a decent chance you actually need fewer interruptions, fewer handoffs, and cleaner rules.
We focus on the operational friction that makes manufacturing expensive: waiting, rework, unclear priorities, and information gaps that force teams to “guess and check.”
Choose a starting point. We’ll still follow the flow end-to-end, because problems love hiding in handoffs.
Identify the true constraint (not just the busiest station) and quantify its impact on throughput, lead time, and labor. We map cycle times, queues, changeovers, and handoffs to show where production is really being governed.
Rework is production you already paid for… twice. We trace defect feedback loops, inspection handoffs, and “tribal fixes” to tighten quality signals and reduce repeat errors.
When priorities change every hour, output drops and stress rises. We clarify dispatch rules, escalation paths, and visibility so the schedule is a plan, not a suggestion.
Manufacturing delays often come from “invisible” work: searching for parts, chasing approvals, waiting for prints, or reconciling mismatched data between systems. We reduce that friction.
We deliver a step-by-step plan that translates manufacturing complexity into clear priorities, owners, and measurable outcomes.
You keep control. We bring clarity, structure, and decision-ready options.
Reduce internal lead time by tightening WIP release rules and stabilizing the constraint.
Cut repeat defects by closing feedback loops and aligning standard work to real conditions.
Increase output without adding headcount by removing waiting and mismatch across steps.
Real numbers depend on your product mix, variability, and current constraints. We quantify targets during discovery so expectations stay honest.
Manufacturing is rarely isolated. If your biggest constraints are upstream or downstream, start here and we’ll connect the dots.
Warehouse flow, fulfillment handoffs, and visibility that prevents “where is it?” fire drills.
Order entry friction, approvals, and the data integrity that keeps production and shipping aligned.
Articles, playbooks, and examples you can use internally.
Whether you’re wrestling with paper forms, manual data entry, or frustrated teams, a short conversation can reveal where small improvements might create real change. Our mission is to arm your team with a data-backed Efficiency Blueprint, allowing you to implement change with confidence, control, and a clear measure of ROI—without the pressure of a software sale. In a world where only a minority of employees report feeling truly engaged at work, even small efficiency wins can have an outsized impact on morale and results.
In this no-pressure call, we will discuss what your Efficiency Blueprint could include:
Ready for an objective analysis? See what your Efficiency Blueprint could look like.
