Proven Results: See What Other Offsite Factories Have Achieved
We don’t just consult—we deliver measurable productivity improvements.
Here’s what past clients have accomplished:
Unlocking Peak Efficiency in Modular Construction: A Case Study in Rapid Process Improvement
The Challenge: A Factory Struggling with Bottlenecks
A modular construction factory, despite its skilled workforce and advanced equipment, faced crippling inefficiencies—idle workers waiting for materials, disorganized tools causing delays, and bottlenecks slowing down production. Every delay compounded across the production line, limiting throughput, increasing costs, and threatening profitability.
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The Solution: A Two-Day Kaizen Blitz with Lean & DMAIC
When traditional problem-solving approaches failed to deliver fast results, the factory turned to my rapid process improvement services, designed specifically for offsite manufacturing. Through a Kaizen Blitz, I applied Lean Manufacturing and DMAIC (Define, Measure, Analyze, Improve, Control) principles to uncover hidden wastes and implement high-impact solutions in just two days.
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Day 1: In-depth analysis of cycle times, identifying and eliminating wasted motion, waiting, and poor tool administration.
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Day 2: Immediate process optimizations, hands-on team training, and implementation of streamlined workflows.​
The Results: Faster Throughput, Higher Productivity
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Gluing process cycle time cut from 65 minutes to 21 minutes (68% improvement).
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Electrical wiring process reduced from 35 minutes to 13 minutes (63% improvement).
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Increased factory-wide throughput without additional labor or capital investment.
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Sustainable process control through updated Standard Operating Procedures (SOPs).​
The Competitive Advantage: Rapid, Measurable Improvement for Offsite Factories
My approach enables modular factories to maximize productivity, reduce costs, and meet growing demand without overhauling operations. By targeting the 9 Offsite Wastes, I help manufacturers streamline production, scale operations, and gain a competitive edge.
Want to transform your factory’s efficiency in days, not months?
Revolutionizing Modular Factory Productivity: A Data-Driven Approach
The Challenge: Uncovering Hidden Inefficiencies Across 24 Factories
A coalition of 24 independently-owned modular factories across the U.S. needed an in-depth evaluation of their labor productivity and process efficiency. With each factory operating under different conditions, leadership lacked clear visibility into where and how inefficiencies were impacting production.
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The Solution: Comprehensive Data Collection & Lean Analysis
Leveraging my expertise in Lean Six Sigma and process optimization, I conducted an extensive multi-factory assessment:
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8+ factories audited, spending a full week in each facility.
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400+ hours of direct production observation and 600+ hours of recorded factory work analyzed.
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70+ employee interviews conducted to capture frontline insights.
Using this vast dataset, I applied Lean waste management principles to quantify value-added vs. non-value-added time across workflows. To enhance the accuracy and efficiency of analysis, I developed a proprietary software tool that streamlined data processing and performance calculations.
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The Results: A Game-Changing Discovery
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Identified a 100%+ improvement opportunity in labor productivity.
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Provided unprecedented quantitative insights into modular factory performance.
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Equipped factory leadership with a breakthrough process understanding to drive long-term productivity, throughput, and profitability gains.​
The Competitive Advantage: Data-Driven Process Optimization for Modular Factories
This project revealed hidden inefficiencies that had gone unnoticed for years, proving that deep operational analysis leads to transformative productivity gains.
Want to double your factory’s efficiency and uncover untapped potential?
Data-Driven Innovation for the Housing Industry: Unlocking Unmet Needs
The Challenge: Identifying Objective, Quantified Innovation Opportunities
A leading housing industry association—representing developers, homebuilders, building product manufacturers, architects, lenders, and construction tech companies—needed to equip its members with data-driven insights at their annual summit. While previous homeowner studies existed, none provided objective, quantified customer needs to guide and de-risk innovation.
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The Solution: Engineerovation™ – A Scientific Approach to Housing Innovation
To bridge this gap, I applied my proprietary Engineerovation™ process to uncover the true, unmet needs of housing consumers:
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Mapped the "jobs" homeowners hire their homes to accomplish, revealing functional and emotional drivers behind housing decisions.
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Designed and conducted a quantitative survey, collecting statistically significant data on homeowner priorities.
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Performed advanced statistical analysis to quantify which needs were most underserved, providing clear direction for innovation.​
The Results: A Breakthrough Innovation Roadmap
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Delivered a prioritized list of high-impact, previously unknown innovation opportunities.
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Provided objective, statistically validated insights to guide product development and investment decisions.
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Equipped housing industry leaders with actionable, de-risked strategies to drive future growth.​
The Competitive Advantage: Innovation with Certainty
By replacing guesswork with quantified insights, I help industry players focus on the solutions that matter most to their customers.
Want to identify the biggest untapped opportunities in your industry?
Engineering Market Leadership in Offsite Construction: A Data-Driven Innovation Strategy
The Challenge: Breaking into the Booming Offsite Construction Market
With explosive growth in offsite construction, my clients—seeking to establish themselves as preferred suppliers—needed a deep, data-driven understanding of modular factory needs. Traditional market research lacked the rigor necessary to pinpoint unmet needs and de-risk innovation investments.
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The Solution: Engineerovation™ – Targeted Market Intelligence for Offsite Suppliers
Using my Engineerovation™ process, which integrates Jobs-To-Be-Done (JTBD) innovation theory with Lean Six Sigma, I systematically identified and measured customer needs across 12 critical factory jobs.
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Spent a full week at each of five independent modular construction factories, mapping workflows and conducting in-depth interviews with job executors.
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Developed and fielded five qualitative and quantitative survey instruments, collecting over 78,000 data points on production processes, procurement practices, and pain points.
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Uncovered 117 unmet customer needs—representing 30% of all identified needs—with direct implications for suppliers.
The Results: Actionable Innovation & Market Differentiation
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Facilitated Focused Ideation sessions with each client to translate findings into high-value product and process innovations.
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Generated 30+ breakthrough innovations, directly informed by quantitative market data.
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Equipped clients with a strategic roadmap to secure long-term market leadership in offsite construction.
The Competitive Advantage: Data-Backed Innovation for Maximum Impact
By using quantitative insights to drive innovation, my clients gained a decisive competitive edge—delivering solutions that modular factories truly need.
Want to become a preferred supplier in offsite construction?
Cultivating Growth: How a Nursery Expanded Its Market with Data-Driven Service Innovation
The Challenge: Strengthening Customer Retention in a High-Churn Industry
A mid-size nursery had a strong base of commercial and residential landscapers, but industry-wide low survival rates among landscaping companies threatened long-term customer retention. My client saw an opportunity to support landscapers’ success—ensuring more stable, loyal customers—but they lacked clarity on what services would provide real value versus market noise.
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The Solution: Engineerovation™ – Identifying and Validating High-Impact Services
Using my Engineerovation™ process, I applied Jobs-To-Be-Done (JTBD) innovation methodology to identify, quantify, and validate service opportunities:
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Conducted multi-phase research to uncover landscapers’ actual business challenges and unmet needs.
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Used quantitative analysis to prioritize real opportunities over anecdotal feedback.
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Developed data-backed service concepts aligned with landscapers’ critical jobs-to-be-done.
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Created a scalable go-to-market strategy to ensure successful implementation.
The Results: A Scalable, Nationwide Service Platform
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Designed a cohesive, high-value services platform to help landscapers survive and thrive.
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Positioned my client as not just a supplier, but a business partner, increasing customer loyalty.
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Developed a scalable model for national expansion, unlocking exponential growth potential.
The Competitive Advantage: Data-Driven Customer Growth
By strategically investing in services landscapers truly need, my client is future-proofing their business, increasing market share, and expanding their geographic reach.
Want to turn customer retention into market expansion?
Maximizing Efficiency in Modular Manufacturing: A Process Optimization Success Story
The Challenge: A Complex, Inefficient Business Process
A consortium of 20+ modular manufacturing facilities struggled with a legacy business process that was inefficient, outdated, and insufficient for managing complex, large-scale construction projects. From lead generation to project completion, inefficiencies slowed the entire pipeline, limiting growth and profitability.
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The Solution: Lean Six Sigma Process Mapping & Optimization
Using Lean Six Sigma principles, I conducted a comprehensive end-to-end process mapping initiative:
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Performed in-depth qualitative interviews with sub-process owners to uncover inefficiencies and hidden roadblocks.
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Mapped the entire business process, detailing inputs, outputs, dependencies, sub-process timing, and critical handoffs to gain full operational visibility.
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Analyzed bottlenecks, delays, and inefficiencies, identifying areas for compression and streamlining.
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Designed an optimized process map, reducing handoffs, eliminating waste, and improving coordination across manufacturing sites.
The Results: An 80% Reduction in Business Development Cycle Time
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Lead-to-Win time reduced by over 80%, accelerating revenue generation.
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Improved cross-facility coordination, ensuring projects move seamlessly from sales to production.
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Enhanced visibility across the entire pipeline, enabling proactive management and decision-making.
The Competitive Advantage: Faster Sales, Faster Projects, Greater Profitability
By optimizing the full business development process, my client dramatically increased efficiency, reduced delays, and positioned itself for scalable growth.
Want to accelerate your modular construction pipeline and maximize throughput?
Breaking Into a New Market: How an Exterior Building Products Company Discovered Its Next Big Opportunity
The Challenge: Declining Market Share & the Need for Innovation
An established exterior building products company was struggling to maintain market share as its flagship products aged and competitors gained ground. They needed to identify their next major revenue driver but lacked clear direction on where to innovate.
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The Solution: Engineerovation™ & Jobs-To-Be-Done for Offsite Construction
Traditional building product manufacturers had overlooked modular construction, considering it a niche market. However, based on my industry insights, I identified offsite manufacturing as a high-growth, underserved customer segment and proposed targeting the job of “protecting a building from water intrusion”—a critical unmet need.
Using qualitative JTBD & Engineerovation™ research, I:
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Conducted in-depth interviews and process observations inside modular factories.
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Uncovered nearly 50 specific, validated customer needs for moisture protection in a factory setting.
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Identified previously unknown pain points that had never been addressed by the industry.
The Results: A Blueprint for Industry-Changing Innovation
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Revealed multiple unmet needs that opened the door for entirely new-to-the-industry products.
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Positioned the client to lead in a rapidly growing market with innovations tailored specifically to modular construction.
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Provided a clear, data-backed innovation roadmap, de-risking R&D investments and increasing the likelihood of commercial success.
The Competitive Advantage: First-Mover Leadership in a High-Growth Market
By leveraging deep industry insight and customer-validated data, my client gained a head start in an untapped market segment, securing new revenue streams and long-term competitive advantage.
Want to uncover hidden market opportunities and create breakthrough products?
Transforming Heavy Equipment Fleet Management: Data-Driven Innovation for Market Leadership
The Challenge: Understanding Fleet Managers’ True Needs
A leading manufacturer of controls and systems for heavy equipment wanted to help fleet managers optimize fleet utilization but lacked a clear understanding of their customers’ real priorities. The company had long assumed what fleet managers needed—yet those assumptions had never been rigorously tested.
The Solution: Jobs-To-Be-Done & Outcome-Driven Innovation™
My team and I applied Jobs-To-Be-Done (JTBD) principles and Outcome-Driven Innovation™ to uncover the true market needs:
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Redefined the job-to-be-done based on actual customer insights, rather than internal assumptions.
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Conducted qualitative research to identify and articulate 100+ clear, objective customer needs.
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Performed statistical analysis to quantify 30 critical unmet needs, revealing high-impact innovation opportunities.
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Developed a data-driven strategy, aligning product development and marketing with actual customer priorities.
The Results: A Market-Aligned Innovation Roadmap
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Identified key product gaps and unmet needs that competitors had overlooked.
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Delivered clear, actionable recommendations for marketing, product improvement, and new product development.
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Enabled the company to differentiate its offerings and position itself as the go-to solutions provider for fleet managers.
The Competitive Advantage: Innovation with Precision & Impact
By quantifying customer needs and identifying gaps in the market, my client gained a roadmap for strategic product development—ensuring that every innovation directly addressed real customer pain points.
Want to align your products with what your customers truly need?
Disrupting U.S. Housing with Automotive Manufacturing: A Strategic Market Entry Plan
The Challenge: Applying Automotive Manufacturing Expertise to Housing
A major overseas automotive manufacturer sought to disrupt the U.S. construction industry by leveraging its advanced manufacturing capabilities to produce affordable, high-performance homes. With the housing crisis escalating, they saw an opportunity to bring efficiency, scalability, and innovation to industrialized construction—but lacked a clear strategy for entering the market.
The Solution: Research-Backed Business Model Innovation
My partners and I conducted exhaustive research into the U.S. industrialized construction landscape, combining deep market analysis with our extensive industry expertise to:
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Evaluate multiple innovative business models for market entry.
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Assess the viability, scalability, and profitability of each approach.
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Develop data-driven recommendations for maximum ROI and market penetration.
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Refine strategies in Phase II, ultimately identifying three optimal business models.
The Results: Actionable Strategies for Market Disruption
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Delivered three fully vetted, high-impact models for strategic entry into modular construction.
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Positioned the client to capitalize on emerging market trends and drive efficiency into housing production.
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Earned recognition from the client for both the innovation and real-world practicality of the solutions provided.
The Competitive Advantage: Unlocking New Markets with Precision
While economic conditions delayed immediate execution, this project demonstrated the power of strategic, research-driven innovation in entering complex, high-growth markets.
Want to identify and execute breakthrough opportunities in industrialized construction?
Bringing the First Integrated Wall System to Market: A Multi-Billion-Dollar Manufacturer’s Innovation Success
The Challenge: Leading the Market with a First-of-Its-Kind Wall System
A multi-billion-dollar building product manufacturer with the broadest product line in the industry saw an opportunity to be the first to market with an integrated wall system solution. However, creating a truly differentiated, high-performance offering required deep market insights, cross-functional collaboration, and a clear go-to-market strategy.
The Solution: Cross-Functional Innovation & Data-Driven Development
As team lead for a cross-functional innovation group, I worked with product, R&D, and marketing leaders across three business units to:
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Conduct extensive market and customer research, uncovering the unique needs of home builders selling high-performance homes.
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Facilitate ideation, design, and product development, ensuring the solution aligned with real-world market demands.
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Develop a first-of-its-kind platform-level wall system, integrating multiple product lines into a seamless, high-value solution.
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Drive marketing, branding, messaging, go-to-market, and distribution strategies to maximize adoption and market penetration.
The Results: A High-Impact Industry First
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Secured an industry-first single-source contract worth $6 million in its first year.
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Positioned the client as a market leader in integrated building solutions.
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Created a scalable, repeatable innovation model for future product development.
The Competitive Advantage: Innovation That Translates to Revenue
By aligning innovation with real customer needs, this project proved that strategic, data-driven product development leads to tangible market success.
Want to bring groundbreaking products to market faster and with greater impact?
Optimizing Heavy Equipment for Construction: Data-Driven Innovation & Market Disruption
The Challenge: Enhancing Material-Handling Equipment for Construction Operators
A major heavy equipment manufacturer sought to improve its products and identify opportunities to disrupt the market for equipment operators moving materials on construction sites. The challenge was understanding where innovation could drive the most impact—whether through new product development, feature enhancements, or cost reduction.
The Solution: Jobs-To-Be-Done Research & Statistical Analysis
Leading a comprehensive customer research initiative, I:
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Conducted detailed qualitative research, mapping the job-to-be-done through in-depth customer interviews.
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Identified 100+ specific customer needs, defining pain points and performance expectations.
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Designed and deployed a comprehensive survey to 250+ customers, quantifying the insights uncovered in the qualitative phase.
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Applied statistical analysis to pinpoint 30 underserved needs (opportunities for innovation) and nearly as many overserved needs (opportunities for cost reduction).
The Results: Actionable Insights for Market Leadership
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Revealed clear opportunities for product innovation and market differentiation.
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Identified areas where cost-cutting could be implemented without sacrificing value.
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Provided a data-driven roadmap for both product improvement and new product development.
The Competitive Advantage: Strategic Innovation for Maximum Impact
By leveraging rigorous customer insights and data analysis, my client gained a clear, quantified strategy to optimize products, reduce costs, and gain a competitive edge in heavy equipment manufacturing.
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Want to turn market insights into game-changing product innovations?
