Somerset Operators — Manufacturing
Plant-floor efficiency, throughput, and process expertise from an industrial engineer who's worked the line and run the business.
What We Do
Most small manufacturers have more capacity than they're using and more cost than they need. We find it — on the floor, not in a spreadsheet.
Assessments
01A structured walk of your plant with an industrial engineer — looking at flow, layout, material handling, idle time, and the gaps that cost money quietly. Most issues are visible within hours if you know what to look for.
Lean
02Identify and eliminate the seven forms of waste — overproduction, waiting, transport, over-processing, inventory, motion, defects — applied practically, not as a certification exercise.
Layout
03Evaluate how material and work move through your plant. Bad layout is a permanent tax on every unit you produce — and most plants grew organically rather than by design.
Throughput
04Understand where your real constraint is and how much capacity you're leaving on the table. Throughput gains from constraint management typically require less investment than adding equipment or headcount.
Quality
05Find the root causes of rework, scrap, and customer complaints — and build the process controls that prevent recurrence rather than relying on inspection to catch problems after the fact.
Equipment
06Assess whether your equipment is being used effectively — or whether changeover time, downtime, or scheduling is costing you capacity you're already paying for.
How It Works
Step 1
01Phil walks your plant floor with you — observing flow, layout, equipment, and process firsthand. No questionnaire-first approach. The point is to see the operation as it actually runs.
Step 2
02A clear findings report tied to throughput and cost impact — ranked so you know what to fix first. Specific, actionable, and written for an owner, not a committee.
Step 3
03Hands-on implementation support on the floor. We don't hand off a report — if you want help making the changes, we're there alongside your team until they stick.
Who It's For
Manufacturers with 10 to 200 employees who want to get more out of the plant they already have — more throughput, less waste, better quality — without a large capital investment or a multiyear transformation project.
Particularly useful for plants that grew fast and never had time to optimize, or operations where the owner knows there's room to improve but can't step back far enough to see where.
Who You're Working With