Client
ForgeWorks
Category
Manufacturing Strategy
Duration
9 months
Completed
Project Overview
Understanding
the Challenge.
ForgeWorks manufactures precision components for industrial and automotive customers from two production facilities in the Midwest. Demand had doubled in three years, and the operating model that served a smaller business was starting to strain.
The Challenge
A Complex Challenge That
Needed a Clear Direction.
Production schedules were built manually, equipment downtime was rising, and teams across the two sites followed different processes for the same work. Leaders spent most of their week solving urgent problems instead of planning ahead.
The goal was to create an operating model that could scale without adding complexity or cost at the same pace as revenue.
Our Approach
A Structured Path
to Results.
01
Research & Discovery
We studied the business, its data, and its people to understand what was really happening.
02
Strategic Planning
We built a focused plan with clear priorities, owners, and measurable targets.
03
Implementation Support
We worked alongside the team to put the plan into action and remove obstacles.
04
Performance Review
We tracked results, refined the approach, and embedded new ways of working.
The Solution
Turning Insight
Into Action.
We mapped every core workflow across both facilities and worked with floor leaders to identify where time, materials, and capacity were being lost.
- Standardized production planning across both sites
- Introduced a preventive maintenance schedule tied to equipment data
- Rebalanced shift structures to match real demand patterns
- Created a weekly operations review with clear ownership for every metric
Results
Measuring
Meaningful Progress.
+42%
Operational Efficiency
-18%
Production Downtime
+27%
Resource Utilization
Client Testimonial
“Their approach was thoughtful, practical, and refreshingly collaborative. We now have a much clearer direction for our next stage of growth.”
Ethan Brooks
Managing Director, ForgeWorks
Let’s Create Your Next
Success Story.
Have a business challenge you are ready to solve? Let’s explore what we can achieve together.