Case Studies
Real plants. Real numbers.
Identify the limiter. Correct it. Make it hold. Here is what that looks like on the floor.
Xcerra
40%
Cycle Time Reduction
Semiconductor capital equipment transfer
A $50M/year revenue generator. Led the cost reduction, transfer, and ramp of complex semiconductor capital equipment manufacturing, owning the engagement from bring-up through stable production output.
- Labor hours per machine reduced from 2,000+ to approximately 1,200, a 40% reduction
- Lead time: ~12 months → ~4 months
- Target production volume exceeded in the first full year in the new facility
Juul Labs
6% → 80%
OEE Improvement
High-speed automation line stabilization at hypergrowth
First-of-its-kind automation line. Started at roughly 6% OEE. Stabilized through downtime-driven prioritization, preventive maintenance discipline, spare parts strategy, and data integrity correction.
- OEE moved to ~40% quickly by eliminating the largest downtime drivers
- Continued iteration drove OEE to approximately 80%
- Maintenance and prioritization systems institutionalized for long-term reliability
RF Code
99.93%
First-Pass Yield
Manufacturing turnaround and leadership
Started as a one-month diagnostic. Extended to nearly two years as acting Director of Manufacturing, overseeing domestic operations and contract manufacturer management.
- Lead time: 13.1 days → 10 days
- On-time delivery: 89.98% → nearly 100%
- Manufacturing leadership rebuilt, leaving behind a fully functional and self-sufficient manufacturing team
Large Industrial 3D Printer Manufacturer
R&D → Production
Full Ownership Transfer
Industrial 3D printer platform launch
Took a next-generation industrial 3D printer platform from R&D prototype to a fully manufacturable system with a repeatable, documented build process.
- Purpose-built tooling and validated test procedures delivered
- Training and work instructions established
- Client could build, support, and deploy at scale without ongoing R&D team involvement