Operation Excellence
A single tolerance mistake in a drawing can quietly trigger rework, scrap, and delays—costing tens of thousands. For SMEs on tight margins, GD&T errors are a major hidden cost. Here’s how they happen, what they cost, and how to fix them.
Operation Excellence
Most manufacturers focus on cutting costs on the shop floor — materials, cycle times, and labour. But the reality is ~80% of costs are locked in during design, long before production. This post shows how design decisions drive those costs — and how to take control of them.
Operation Excellence
Most manufacturing SMEs are losing $50,000 or more each year to inefficiencies they can't see. The problem isn't a lack of effort — it's a lack of visibility. When you map your processes end-to-end, the waste reveals itself, and the savings follow.
A hardware assembly line was losing 8.7 hrs/week and had 8% rework due to poor process design. A $780 jig cut cycle time by 30%, reduced rework by 74%, and saved ~$27.6k/year. Payback in under 11 days.
Many managers think processes are fine if products get made—but 'working' isn’t the same as 'efficient.' I’ll show how one shopfloor study uncovered $87,000 in hidden waste and turned it into real savings
Poorly specified compression springs are a hidden cause of assembly issues. Binding, buckling, and inconsistent loads lead to stoppages, rework, and scrap. This post highlights 5 common design mistakes, their cost impact, and a practical checklist to prevent them.
Every dimension has a tolerance—but in assemblies, they stack up. Small variations become rework, scrap, and hidden labour cost. This post breaks down the real financial impact of tolerance stack-up—and how to fix it without over-engineering.
Most consultants haven’t built tools or faced failing runs at 5am. I have. Over 25 years—from toolmaker to operational excellence—I’ve learned where manufacturers lose money and how to stop it. That’s the foundation behind CostDown and why it matters.
Strategist.press shares practical strategies, tools, and insights for project managers, engineers, and business leaders. Learn how to optimise processes, reduce costs, and apply PMP, Lean, and Six Sig
A hardware assembly line was losing 8.7 hrs/week and had 8% rework due to poor process design. A $780 jig cut cycle time by 30%, reduced rework by 74%, and saved ~$27.6k/year. Payback in under 11 days.
Many managers think processes are fine if products get made—but 'working' isn’t the same as 'efficient.' I’ll show how one shopfloor study uncovered $87,000 in hidden waste and turned it into real savings
Many Australian manufacturers think they’ve “done Lean” after 5S. But 5S is just the entry point—not the system. Real gains in cost, cash flow, and competitiveness come from applying Lean as a full operating philosophy, not a one-off exercise.
In most SMEs, improvements stall not from lack of ideas, but from waiting for approval. The fastest, lowest-cost gains come from frontline-driven action. Build a culture that empowers operators to fix issues—unlocking sustained cost reduction and stronger cash flow.
Poorly specified compression springs are a hidden cause of assembly issues. Binding, buckling, and inconsistent loads lead to stoppages, rework, and scrap. This post highlights 5 common design mistakes, their cost impact, and a practical checklist to prevent them.
Design for Manufacture (DFM) isn’t optional—it locks in 70–80% of your cost. Poor early decisions drive complexity, waste, and margin loss. This post breaks down 7 common DFM mistakes in SMEs—and how to fix them before they hit your bottom line.
Every dimension has a tolerance—but in assemblies, they stack up. Small variations become rework, scrap, and hidden labour cost. This post breaks down the real financial impact of tolerance stack-up—and how to fix it without over-engineering.
Most SMEs chase savings in labour and materials—but the biggest lever is product design. Tight tolerances, excess parts, and poor material choices quietly drain cash. Here are five simple design changes that can save $20k+ a year.
Most consultants haven’t built tools or faced failing runs at 5am. I have. Over 25 years—from toolmaker to operational excellence—I’ve learned where manufacturers lose money and how to stop it. That’s the foundation behind CostDown and why it matters.
