High Value Manufacturing Consulting

The latest blog post from HVM’s Becky Ferrell is posted! Hear about her experience as a Supply Chain Professional “in the wild”… In a career in Manufacturing Supply Chain, professionals quickly learn two key principles: inventory is both a necessary evil and a critical aspect of operational success. Inventory, while costly and prone to waste (through storage, transport, and potential obsolescence), is essential to ensuring production continuity and preventing costly shortages. Supply chain professionals are also trained in maintaining rigorous inventory accuracy, using methods like cycle counts, FIFO systems, and regular checks to avoid costly mistakes. Outside the workplace, such professionals often apply these principles to daily life, where disorganization in other industries/environments —such as inaccurate stock counts or poorly managed shelves—can be very frustrating. Becky’s blog highlights the frequent disconnect between her professional Supply Chain experience in lean manufacturing & inventory management versus her personal experience as a consumer “in the wild.” As she says, “It’s not something you get over.” #highvaluemanufacturing #manufacturingconsulting #automotivemanufacturing #supplychain #leanmanufacturing #inventorymanagement #performanceimprovement #productioncontinuity

In the high-stakes industry of Aerospace and Defense Manufacturing, even slight lapses in product quality and operational efficiency can have significant repercussions. The military must rely on well-designed and carefully manufactured weapons that work the first time they are deployed. Quality is not negotiable. When skilled positions are filled with inexperienced resources or left vacant with no qualified candidates, the manufacturers’ day-to-day operations will suffer. Plant performance will slip, and product quality may be jeopardized. High Value Manufacturing’s supplemental skilled labor resources sustain and enhance clients’ manufacturing processes. Our team steps in to fulfill daily duties for open positions, ensuring that production remains uninterrupted.?Our approach – through operational assessment, hands-on daily work functions, process improvements and documentation, on-the-job training and mentorship, and structured transitional support – is designed to sustain and propel operational success for manufacturers. HVM’s detailed project plan consists of six pivotal activities designed to maximize performance during supplemental resource placement and sustainability of job functions post-engagement. Aerospace and Defense companies do not just manufacture products; they create systems that are crucial to national security and passenger safety. HVM implements disciplined quality standards to manufacturing processes that simultaneously promote reliable, consistent output of the highest quality. More efficient manufacturing operations can achieve customer quality requirements while also achieving critical Key Performance Indicators. Thanks to Patrick Smith, HVM’s Lead of Aerospace & Defense / Supplier Quality Management Strategies, for this blog post. #highvaluemanufacturing #manufacturingconsultant #aerospacemanufacturing #defensemanufacturing #operationalexcellence?#manufacturingquality #qualitystandards #continuousimprovement #skilledlaborresources

Equally important are the additional cuts expected before the need of this year. Now is the time to plan impact on your business.

Chaos. That’s the word I chose in my blog post to describe the present state of manufacturing quality. Daily reports of poor manufacturing quality permeate the news. Stories of recalls, warranty claims, lawsuits, and dissatisfied customers are regularly reported across a multitude of industries. Let’s use the Automotive Industry as an example: Over the five years ending in 2022, the U.S. averaged more than 1,000 car recalls each year, or about 27 per day. Until 2016, the U.S. had not exceeded 1,000 car recalls in any year going back to at least 2002. I analyzed J.D. Power’s most recent Initial Quality Study to better understand recent trends. The review of data reveals an industry-wide issue that is not related to any one OEM or supplier. We are seeing a significant change in the dispersion of the data from the 2010 to 2019 period and the most current five years (2020 to 2024). This indicates rapid deterioration of capability within the industry. Something I found most interesting from my review: In the most recent 5-year period there has been no ‘clear’ stand out from a quality measurement perspective, good or bad. Quality basics start with a disciplined approach to the Product and Manufacturing Process design such as Advanced Product Quality Process (APQP), followed during the implementation phase with adherence to the global standards such as ISO 9001. U.S. manufacturers have a huge opportunity to make QUALITY a competitive advantage. Who will step forward? #highvaluemanufacturing #manufacturingquality #manufacturingconsultant #automotivemanufacturing #qualitymanagementsystem #automotivequality

Following a competitor's lead may not be in the best interest of your own facility nor worth the time of valuable labor resources to pursue the same course of action. Many years ago, Becky Ferrell was tasked by her boss to streamline expendable packaging used by component suppliers to five containers. His motivation was to follow in the footsteps of the plant’s competitor! Much time and energy was spent evaluating possible container designs and their impact on quantities, delivery periods, inventory storage, workflow, trailer fit, and shipping costs. The boss’s plan would result in inefficiency and higher costs, per Becky’s reported findings. The wisdom from this story is: Focus on imperative tasks to fix legitimate issues in the plant. Spending scarce resources “tilting at windmills” means delaying substantive projects that will yield a positive business result or competitive advantage. #highvaluemanufacturing #manufacturingconsultant #automotivemanufacturing #operationalimprovement #streamlinepackaging #inventorymanagement #OEMsupport

The U.S. Automotive Industry is in a state of flux. Would you agree? I wrote this blog to share some of my research and observations about today's changing automotive market and uncertainty about its future. We are seeing fluctuating market demands, shifting government priorities, infrastructure issues, and cost pressures. Additionally, the rush to introduce Battery Electric Vehicles (BEV) has led to over-stressing the new product launch capacity of many OEMs and their suppliers. A rush to market has serious quality implications. New technologies, fewer experienced workers, and expedited launch timelines have compromised application of quality principles in the design and manufacturing processes. The principles of Advanced Product Quality Planning (APQP) are critical for ensuring a product “satisfies the customer and meets all performance and quality requirements.” Disregarding the disciplined, structured process of APQP and its necessary learning cycles results in poor quality products – as evidenced by product failures, recalls, complaints, and safety concerns. The recent J.D. Power’s Initial Quality Study confirms the prevalence of new vehicle quality issues. At High Value Manufacturing, we provide operations expertise and performance improvement services for manufacturers. Our team of highly skilled, highly experienced resources provide technical support for manufacturers requiring immediate labor solutions, with capabilities to provide an entire cross-functional launch team experienced in the application of the APQP process. #highvaluemanufacturing #manufacturingconsultant #APQP #qualityprinciples #productlaunch #automotivemanufacturing #USautomotive #USmanufacturing #onshoring

In Aerospace and Defense industries, manufacturers strive for precision, reliability, and efficiency. KPIs are essential tools for navigating complexities of manufacturing/assembly operations and for driving continuous improvement in a highly competitive and regulated environment. In High Value Manufacturing’s latest blog post, our Lead of Aerospace and Defense Patrick Smith explains ten important KPIs and their relevance to the operational performance of A&D manufacturers. By focusing on these indicators—Safety, On-Time Delivery, First Pass Yield, Cost Per Unit, Manufacturing Lead Time, Supplier Quality Rating, Return on Investment, Compliance Rate, Inventory Turnover Ratio, and Scrap Rate—A&D manufacturers can enhance their performance, meet stringent industry standards, and consistently deliver high-quality products to their customers. #highvaluemanufacturing #manufacturingconsultant #aerospaceanddefensemanufacturing #operationalexcellence #qualityprocesses #continuousimprovement #manufacturingKPIs

In this Federal Newswire interview my colleague Harry Moser addresses China’s industrial complex, U.S. defense priority, nuclear power, and reshoring as a smart business decision. Harry and his organization, RESHORING INITIATIVE, are a preeminent source of data and trends related to U.S. reshoring. We share his enthusiasm about the U.S. as a preferred choice for basing operations, and we expect to see significant growth in the manufacturing sector as a result. #highvaluemanufacturing #USmanufacturing #automotivemanufacturing #manufacturingconsultant #onshoring #reshoring

I cannot believe it has been 10 years since I started my business with the goal of helping small manufacturers perform better. I cannot thank my team enough for the contributions they’ve made to this achievement! We still have work to do! #highvaluemanufacturing #manufacturingconsultant #HVMcelebrates10 https://lnkd.in/eiuS4uss