Full Factory Turnaround
From (-6%) EBT to (+29%) EBT.

Uniform black powder coating complicated the visual discernment between different components. All parts appeared as similar geometric shapes, making identification impossible without systematic labeling or measurement processes. This created the fundamental challenge that drove the need for powder coat-resistant identification solutions. 

Copper components with similar hole patterns and geometric features were difficult to distinguish after transport. Transport-related damage and disarray compounded identification challenges, as components required both visual inspection for quality and geometric identification for proper assembly placement. 

See how much time this wasted - Case Study below.

Components remained in production areas long after their associated jobs were completed. This created confusion about current vs. obsolete inventory and contributed to workspace congestion. 

Lack of systematic inventory turnover protocols resulted in accumulation of materials no longer needed for active production. 

No opportunity for line clearance or job changeovers. 

Large panels and components spilled onto production floors, creating obvious safety hazards and "damage from stock" process control incidents. "Inadequate material handling procedures" (forklift drove over the spilled parts) highlight the need for improved storage locations and employee accountability to maintain both safety and product quality. 

Accumulation of unusable or obsolete components required systematic removal and disposal processes. Mixed materials on the production floor created workflow disruption and safety concerns, necessitating immediate cleanup and proper waste management protocols. 

Improper storage methods resulted in components sliding and falling from designated areas. Poor stacking techniques and inadequate securing methods created recurring material displacement problems, requiring repeated cleanup efforts and presenting ongoing safety hazards. 

Disorganized storage methods created inefficient workflows where components were placed randomly without systematic location tracking. Assembly teams resorted to temporary storage solutions, planning to locate correct parts later in the process. This approach led to extended search times and frequent misplacement of critical components. 

Even parts that were received with paper tags contained incorrect information, forcing assembly teams to rely on manual measurements with millimeter accuracy and 3D model specifications for component identification. This created significant delays and potential assembly errors when teams could not quickly verify component specifications. Parts were too similar in appearance but were not interchangeable in the design. DFM miss. 

Functionally different but similar appearance 

These screws appeared identical during assembly operations. While visually indistinguishable in normal lighting conditions, one component was a self-tapping screw designed to intentionally gouge metal and form threads - critical for specific design requirements. 

The remaining screws were standard fasteners. Though functionally incompatible, assembly teams could easily interchange them due to their identical appearance, and proximity of use. This led to many errors and product failures. 

Barely perceptible in this photo: standard and TapTite screws mixed together. Both screws were #10 x 5/8" nominal, but one is designed to be a self-tapping screw, permanently threading itself into solid holes. The other is engineered for hardware fastening (nut or PEM nut). 

These two quite identical screw types should not have been specified for the same unit. Intentional differentiation by diameter and/or length would have prevented this. 

Using a TapTite screw with a typical nut (or standard screw in untapped hole) can create a flawed connection. This is especially worrisome in these seismic-rated cabinets. 

The facility operated under a "structured" but inefficient search protocol when components could not be immediately located. 

The standard process required assembly workers to conduct individual searches for 30 minutes, followed by 30 additional minutes with added engineer assistance, then 30 more minutes with assembly lead support. 

Components not found within this 90-minute window required emergency expediting, creating significant production delays and increased costs. 

Notice the footprints on the largest flat panel. Workers frequently navigated hazardous conditions, including walking on top of painted parts while searching for items. At least one slip and one trip occurred on and around these tightly concentrated pallet zones. 

Improperly stored components with protruding hardware created some noticeable safety risks for assembly teams. Poor storage techniques combined with inadequate part identification made component retrieval both dangerous and difficult. 

Introduced systematic parts containment using repurposed materials (discarded cardboard boxes) when budget constraints prevented even the minimal purchase of plastic containers. The company had operated at a loss for too many months to invest any dollars into equipment or materials. The boxes immediately eliminated component mixing and enabled efficient shelf placement in single motions, replacing time-intensive manual sorting processes that previously required extended floor-level searches with measuring tools. (30-50 minutes per pallet) 

The solution delivered immediate organizational benefits while demonstrating cost-effective problem-solving using available resources.

Standard Industrial Engineering Detailed Study Below

Systematic organization gradually improved workspace safety and efficiency, including establishment of walkable aisles between (some) storage areas. The transition from hazardous floor storage to organized point-of-use positioning faced initial resistance, as facility leadership preferred centralized rear-wall storage concepts over line-side shelving.

The reorganization process revealed significant component duplication issues, with identical parts distributed across 3, 4, 5, and even 6 different shelf and rack locations, without documentation or coordination. Fragmentation had occurred over time without the group's awareness, creating inefficiencies in both storage utilization and retrieval processes.

Consolidating duplicate inventory to designated locations required several months of systematic identification by measurement with tape measures and concerted relocation efforts, but eventually proved an added benefit of the new efficient inventory management and component accessibility.

Implemented vertical storage solution for narrow components enabling automatic length-based sorting. This arrangement allows parts to naturally organize themselves by dimension, significantly reducing search time and improving installation accuracy. The self-sorting mechanism eliminates manual organization requirements while ensuring consistent component accessibility for assembly teams. These are the parts that were originally strewn in a shelf and covered in hard hats. 

Developed comprehensive visual communication materials to enhance assembly team understanding of critical hardware installation procedures. These educational bulletins provide clear visual guidance on proper installation techniques, highlighting the importance of correct hardware selection and placement for long-term product functionality and safety compliance. The materials serve as reference guides to support consistent assembly quality and reduce installation errors. 

Established systematic shelving organization using high-visibility labels leveraging existing printing contract. The facility's printing agreement provided unlimited black and white pages printed at no additional cost, while color pages cost $0.40 each. This delivered high contrast organizational improvements while maximizing cost efficiency through strategic use of available resources. 

Introduced batch labeling for powder coating operations - the most transformative improvement implemented at the facility. Previously, part numbers existed only in engineering 3D models, with all component identification relying on visual recognition by a single experienced employee who had built units personally for over a decade. Mixed pallets of painted parts arrived daily (typically up to 12 pallets), creating identification challenges that halted production flow.

Initial resistance to the labeling concept centered on concerns that identification tags would not survive the powder coating oven cure process. Multiple team members expressed skepticism about tag durability through the high-temperature coating operation. This objection necessitated development of heat-resistant identification solutions that could maintain legibility and adhesion throughout the entire powder coating cycle.

Tested heat-resistant identification solution featuring protective layers that could be removed post-coating to reveal part numbers. The system utilized white pull tabs and yellow protective films over handwritten component information. 

However, implementation challenges included reverse-writing numerals (onto the back side of the adhesive tag, because the front side / top layer was only there to be ruined by paint and was designed to be peeled away subsequently), permanent tag placement leaving some areas uncoated, and potential oxidation risks. 

While functional, the process complexity and aesthetic concerns led to exploration of alternative identification methods. 

Developed aluminum foil wrapping technique to protect paper identification tags and QR codes through the powder coating process. The foil maintained complete tag functionality and information integrity, preserving both part numbers and job details for post-coating identification. The method demonstrated 100% QR code readability success rates.

However the manual wrapping process prompted further solution refinement. 

Demonstrated 100% QR code readability and functionality when protected by aluminum foil wrapping. While this method successfully preserved all tag information and scanning capabilities, the manual wrapping concept was not well received by the fabrication team. 

Shown: Backside of Embossable Tag.

Developed the optimal identification solution using embossable aluminum-clad tags with cardstock core construction. This innovative design allows ballpoint pen pressure to permanently engrave part numbers and job information directly into the aluminum surface of the wire-tied tag. 

The embossing process creates durable identification that survives the powder coating process while requiring minimal additional fabrication time. This solution combined durability, functionality, and ease of implementation to become the standard identification method for all powder-coated components. 

Demonstrated successful component identification system with visible embossed part numbers surviving the powder coating process on finished gray components. This breakthrough achievement enabled systematic tracking and identification of painted parts for the first time in company history. 

The legible embossed numbers, directly gouged into the tag, created new possibilities for inventory management and assembly efficiency by eliminating the guesswork previously required for component identification. 

Legibility was also satisfactory on black parts, with deeper engraving being easiest to read. Photo of a black tag is below.

Visibility did not rely on ink contrast, contrary to this first example. 

For instance, you can still read the leading digit (4) although the powder coat has obscured the ink. 

Collaborated with IT specialist to develop custom web-based parts database system. The database provides comprehensive component information based on part number input, including dimensional specifications, "where-used" applications, quantity requirements, and detailed part descriptions. This system replaced generic visual identification methods (such as "large black rectangle" or "flat black rectangle") with precise technical nomenclature.

Additional database features include primary and secondary storage location assignments and part family categorization for efficient filtering and component reuse. The system established a foundation for systematic inventory management and enabled data-driven decision making for component allocation and storage optimization.

Expanded database functionality to include comprehensive transfer tracking capabilities monitoring fabrication, shipping, and receiving activities. This system provides real-time visibility into component location status with timestamp and last known location. The transfer tracking feature enables complete supply chain visibility from fabrication through final assembly, supporting improved planning and inventory management decisions. 

Achieved full database functionality through systematic refinement and testing over several months of implementation. The iterative development process incorporated user feedback and operational requirements to optimize system performance and usability. This was not easy, and several times the database didn't treat inventory counts as intended. The temporary slowdowns and do-overs were worth the trouble once the system was functional and accurate.

 This comprehensive parts management platform established the foundation for systematic inventory control and operational transparency throughout the company - across multiple facilities. 

Established systematic storage location assignments with clear addressing system enabling efficient component location by any team member. This solution eliminated previous issues where identical part numbers were scattered across multiple random shelf locations throughout the assembly building, and untraceable in every way. The systematic approach replaced ad-hoc storage methods where components were placed in any space available, creating a foundation for predictable inventory management and significantly reducing component search times. 

Developed priority signaling system to optimize daily receiving operations for 10-12 incoming pallets of painted components. The color-coded priority system enables various assembly teams and departments to communicate urgent component needs to receiving personnel, ensuring critical items are shelved first to maintain production flow. 

This prevents production delays by ensuring immediate access to time-sensitive components while allowing less urgent items to be processed systematically, later, avoiding the disruption of current operations. 

Developed customizable wiring and quality checklist system to replace generic, overpopulated documentation that applied universal formatting to all builds regardless of applicability.

The new system eliminated unnecessary sections for specific builds, reducing documentation complexity and improving checklist relevance. This targeted approach created more focused quality control procedures by presenting only applicable inspection criteria, though implementation faced adoption challenges during the transition period. 

Also the font size increased from 2 to 12.

My Human Factors Engineering Professor wrote this paper on the effects of reading during motion.

Working in a factory is not like working at a desk, and reading from a page in a factory task is not like reading at your desk. 

Implemented direct material routing visual messaging for large flat panels, directing them immediately to final staging department for organized shelving rather than temporary storage in building rear areas. This workflow improvement eliminated extended floor storage periods that created safety hazards and component damage risks. The direct routing ensured panels remained accessible and protected while reducing handling steps and improving overall material flow efficiency throughout the facility. 

The enhanced design uses clear graphics and bold messaging to ensure consistent workflow adherence, directing specialized panels to appropriate staging areas. 

consolidation and labeling system in staging area enabling efficient location of countless unique panels, and eliminating manual measurement requirements. The organized vertical storage approach eliminates time-consuming search processes and reduces dependency on finding the lost tape measure.

Clear identification labels provide immediate visual confirmation of panel specifications, supporting faster stocking and assembly operations, improved workflow efficiency. 

Developed comprehensive production status dashboard using Google Sheets platform, providing real-time visibility across all manufacturing areas including laser cutting, waterjet, press brakes, assembly stations, and quality control processes. The system enabled plant-wide editing capabilities and immediate status updates for all functions and departments. This cost-effective solution created instant communication of production bottlenecks and priority issues without requiring additional software investments or IT infrastructure changes. 

I would recommend this to every young or struggling factory. Caveat: the screens need to be perpetually visible to responsible parties, to ensure best response time. 

Implemented comprehensive scanning system for outgoing parts with automatic packing slip generation, creating seamless documentation flow between fabrication and assembly operations. The system captures part quantities and specifications during scanning, generating paper packing slips that accompany painted components through the powder coating process. 

This documentation provided receiving teams with detailed component information, enabling efficient check-in procedures and accurate inventory updates. The integrated approach saved significant time during receiving operations while supporting the complete traceability of all parts throughout the supply chain. 

Developed comprehensive documentation system for fabrication quality issues to improve communication between assembly and fabrication teams. 

The photo in this example addressed approximately 500 incorrect components received in one day. The rework process gained some structure through detailed tracking and clear return instructions, including scheduling information with requested return dates. 

The documentation system bridged communication gaps and provided fabrication teams with specific quality requirements and corrective action guidance, supporting continuous improvement in upstream manufacturing processes. 

Created detailed visual assembly guides for transformer wiring hardware installation to address recurring assembly errors. These comprehensive instructions specify proper component sequence, orientation, and placement using clear graphics and labeled components ("Flat, Lugs, Copper, Flat, Lock, Nut"). 

The visual aids address knowledge gaps in assembly procedures, reducing dependency on tribal knowledge while ensuring consistent installation quality. This documentation approach supports standardized assembly practices and enables multiple team members to perform complex wiring operations correctly.

Developed comprehensive visual installation guides for grounding strap procedures to address recurring electrical connection errors. The step-by-step instructions specify proper component sequence and orientation (Star, Ground, Flat, Lock, Nut) with emphasis on critical safety requirements for electrical grounding connections. Clear visual guidance addresses installation challenges and ensures consistent assembly quality while highlighting the importance of proper grounding for electrical safety and product functionality. 

Established right-sized vertical storage system integrating all above comprehensive labeling and cataloging capabilities, enabling efficient component location and accurate inventory counting. This systematic approach transformed facility operations from reactive inventory management to proactive planning and control. 

The organized storage system provided complete visibility into available components and quantities, supporting inventory planning and production scheduling decisions. 

This foundation enabled transition from unpredictable material availability to systematic inventory management supporting consistent production flow.

These parts arrived to the assembly facility on a truck. I started to sort them back into piles but just had to pause to get this photo.

See Case Study Below for Detailed Industrial Engineering Data

Look how much time this saved 👇