Industries
Manufacturing consulting: operational efficiency and quality systems
Industrial project management, Lean Manufacturing optimization, Six Sigma, ISO 9001 for manufacturing, operations digitization. Certified PMs with experience in production plants and complex logistics operations.
We understand the challenges of industrial production
Manufacturing and logistics face constant pressure: reduce costs without sacrificing quality, improve production efficiency, minimize waste, meet deliveries on time, manage complex supply chain, maintain strict quality standards. Margins compress due to global competition and rising raw material costs. Companies that don't continuously optimize lose competitiveness.
Alternative has experience implementing operational improvements in manufacturing plants and distribution centers: Lean optimization (waste elimination, cycle time reduction), Six Sigma for defect reduction, ISO 9001 for production process standardization, capacity expansion project management, MES/WMS system implementation. We understand 24/7 operations, production constraints, inventory management (raw materials, WIP, finished product), and need for complete traceability for quality and compliance.
Critical challenges of the industrial sector
Pressure to reduce operating costs
Margins compressing due to global competition and rising costs. Need to optimize every point of process: labor, raw materials, energy, waste, logistics.
Suboptimal production efficiency
OEE (Overall Equipment Effectiveness) typically 50-65% vs 85%+ world class. Losses from: machinery downtime, slow product changes, quality defects, micro-stops.
Process waste (8 Lean wastes)
Overproduction, waiting, unnecessary transport, overprocessing, excessive inventory, unnecessary movements, defects, underutilized talent. Waste represents 20-40% of cost.
Inconsistent quality control
Quality defects generate: rework (cost), scrap (material waste), customer returns (cost + reputation). Need for statistical process control (SPC) systems.
Complex inventory management
Difficult balance: sufficient inventory to not stop production vs excess immobilized capital. Batch management, expirations (pharmaceutical, food), FIFO/FEFO, traceability.
Inefficient logistics and supply chain
Late deliveries to customers, high logistics costs, unoptimized routes, limited visibility of in-transit inventory, supplier problems.
How Alternative supports manufacturing and logistics companies
Industrial Project Management
PMP® certified Project Managers for complex projects in manufacturing plants and logistics operations: capacity expansion, new production line implementation, automation projects, MES/ERP system implementation, plant relocations, continuous improvement projects.
- Capacity Expansion (plant expansion, new lines, distribution centers)
- Automation and Industry 4.0 (robots, MES systems, IoT, system integration)
- ERP/MES/WMS Implementation (SAP, Oracle, management systems)
- Continuous Improvement Projects (Kaizen, Lean Six Sigma)
- Certifications and Compliance (ISO 9001, ISO 14001, ISO 45001, GMP, HACCP)
Lean Manufacturing Optimization
Implementation of Lean Manufacturing and Six Sigma methodologies to eliminate waste, improve efficiency, reduce costs, improve quality. Certified Lean consultants with experience in industrial plants.
- VSM (Value Stream Mapping): Value flow mapping to identify waste
- 5S: Systematic organization and cleaning (increases efficiency 10-20%)
- Kanban: Pull system for inventory management (reduces WIP 40-60%)
- SMED: Product change time reduction (target: <10 min)
- TPM (Total Productive Maintenance): Total productive maintenance
- Kaizen: Continuous improvement with structured events
Operating cost reduction: 20-35% | OEE improvement: +15-25 points | WIP inventory reduction: 40-60% | Lead time reduction: 30-50% | Productivity improvement: 20-40%
ISO 9001 Manufacturing
ISO 9001:2015 quality management system implementation for manufacturing. Production process documentation, quality controls, traceability, non-conformity management, internal audits.
- Standardizes production processes (reduces variability)
- Ensures complete traceability (critical for recalls)
- Improves quality control (reduces defects 30-50%)
- Requirement of corporate clients / tenders
- Base for other ISOs (14001 environmental, 45001 safety)
Production processes, quality control, inventory management, maintenance, purchasing, product design (if applicable), supplier management, storage and dispatch.
Frequently Asked Questions
Lean applies to any size: Small plant (20 employees, 1 line) to large (500+ employees, 10+ lines). Lean principles are universal: eliminate waste, continuous flow, continuous improvement. Difference: Project scale and complexity. Small plant: Lean project 3-4 months, improvements 15-25%. Large plant: project 8-12 months, improvements 20-35%. Positive ROI in both cases (typical payback 6-18 months).
No. Lean is implemented with plant operating. Methodology: (1) Diagnosis: Without stopping, we observe operation, (2) Kaizen Events: 2-3 day workshops with team (line can continue with rest), (3) Changes: We implement during maintenance shifts or weekend, (4) Re-layout: If necessary, during scheduled annual shutdown. Objective is to improve while producing, not stop 3 months to optimize.
Well implemented, helps significantly: Documents processes (reduces operator-to-operator variability), standardizes quality controls (fewer defects), ensures traceability (critical for recalls/audits), facilitates training of new operators (clear procedures). Poorly implemented: Can generate bureaucracy if excess unnecessary documentation. Alternative designs pragmatic ISO: documents essential, controls that add value. 90% of manufacturers report ISO as net benefit after 18 months.
Experience in multiple manufacturing verticals: food and beverages, pharmaceutical, plastics, metalworking, textile, electronics. Although specific processes differ, Lean and ISO principles apply universally. For regulated industries (pharmaceutical GMP, food HACCP), we have experience in additional compliance beyond ISO 9001. If very specific manufacturing, initial learning curve of technical particularities but proven methodology.
Does your plant need to improve operational efficiency?
Free 30-minute Lean evaluation. We review operation, identify main waste and estimate improvement potential.