Solving Production Capacity Challenges

Our Core Services Include:

• Capacity audits & throughput modeling
• Line design, tooling setup, industrialization planning
• Ramp-up support & bottleneck resolution
• Readiness assessments from prototype to full-rate launch

Case Insights:

• Increased capacity (turnaround) for a large automotive OEM robotic and manual line
• Scaled EV production lines for Rivian (battery packs, final assembly)
• Led production startup for thermal camera systems in cleanroom aerospace
• Ramped production of Gulfstream G650 composite structures
• Supported Airbus A350 system launch readiness

Execution-Focused Leadership

Leadership:

• Interim leadership for distressed operations
• Executive leadership for plant turnarounds
• Program direction for cross-regional transformation
• Organizational design for lean, high-performing cultures
• Cross-functional alignment and performance coaching

Case Insights:

• Transformed underperforming automotive plant: +115% output in 7 months
• Directed 15 cross-functional projects in HR, Logistics, and Engineering
• Oversaw 450+ employees with focus on safety and culture
• Headed PMO driving execution across HR, IT, Operations in the Americas
• Built teams to launch EV platforms with full accountability
• Led Lean transformation for Ariane 5 booster manufacturing at SABCA
• Implemented organization-wide change using visual tools
• Directed industrialization and production ramp-up for G650 and A350 components
• Managed international expert teams for eVTOL feasibility study
• Negotiated industrial scope and funding for military offset programs

Supply chain

End-to-End Supply Chain Capabilities:

• Supplier sourcing and readiness assessments
• Logistics optimization and flow integration
• Make-vs-buy and manufacturing footprint analysis
• Supplier relocation and ramp-up planning
• Disruption management and risk mitigation strategies

Case insights:

• Established end-to-end supply chain from the ground up for a greenfield OEM operation.
• Negotiated supplier contracts and introduced freight carriers
• Drove ERP integration and performance KPIs
• Directed EV supply chain launch at Rivian
• Delivered stable production ramp-up at greenfield site
• Built greenfield supply chain for 7,200 vehicles/year
• Reengineered distribution networks in Asia and South Africa
• Directed resolution of supplier crises to prevent shutdowns
• Evaluated high-risk suppliers and implemented corrective plans
• Optimized packaging solutions for Tier 1 & 2 suppliers

Technology

Technology Assessment and Support:

• Process and automation readiness reviews
• Electronics, composites, and propulsion system integration
• ERP and digital system implementation support
• Technology maturity and scalability assessments
• Industrialization planning and production technology validation

Case insights:

• Automated EV production systems for Rivian
• Validated manufacturing processes for high-volume EVs
• Implemented ERP systems to streamline production and supply chains
• Led benchmarking and VAVE cost-reduction initiatives at Ford
• Directed technology and complexity optimization at General Motors
• Launched thermal camera production in cleanroom environment
• Introduced Lean principles in Ariane 5 launcher manufacturing
• Led composite tail skin and beam production for Gulfstream G650
• Industrialized flap mechanism and fairings for Airbus A350
• Managed feasibility and tech planning for eVTOL aircraft

Financial Analysis and Evaluation

Evaluate and propose supplier financial due diligence:

• Supplier stability and investment potential
• ROI modeling, credit analysis, and debt capacity assessment for readiness validation
• Advisory on financing structures including vendor finance and asset-based lending
• Support for relocation, site expansion, and operational transition risk planning
• Audit readiness and alignment of financial controls with OEM and investor standards