How It Works | High Caliber Operations
The Process

How It Works:
Measure → Fix → Install

You'll know what's leaking per shift, what's causing it, and what the next step is.

No prep deck. Just labor, output, downtime.

CALCULATE MY EXPOSURE See Services

MARGIN RECOVERY FIRST. LEAN DEPLOYMENT SECOND.

Step 0

The 20-Minute Exposure Call

Before anything goes on-site, I spend 20 minutes with you to confirm fit, estimate exposure, and decide if Phase 1 makes sense.

  • Confirm fit — size, environment, urgency
  • NDA available before any data exchange
  • You share basic numbers: labor, output, downtime, overtime
  • I estimate rough exposure with you live on the call
  • If it makes sense, I schedule Phase 1 dates
If you're not a fit, I'll tell you on the call.
Timeline at a Glance

From first call to installed system.

Step 0
20 Min
Exposure Call
Phase 1
2 Days
On-Site Margin Diagnostic
Phase 2
4–8 Wks
Rapid Operational Correction
Phase 3
6–12 Mo
System Installation
The HCO Operating System

No Ambiguity. Three Steps.

01

Measure

Time-stamps + throughput behavior + your labor and production data → exposure in dollars.

Output: Per-shift leakage + where it's happening.
02

Fix

Constraint first. 1–2 outcomes only.

I stabilize the bottleneck and remove the friction reducing output.

Output: Stabilized constraint + measurable capacity increase.
03

Install

Leader routines + scorecards + escalation rules.

Output: Protected margin + self-sustaining floor.
You'll leave with a simple daily cadence your leaders can run without me.
Phase 1

The 2-Day Margin Diagnostic

Two days on your floor. No prep deck required. Here's exactly what happens.

If you can show me headcount, output, downtime, and overtime, I can do the math.

Day 1 — Observe
  • I walk the flow end-to-end across active stations
  • I time-stamp delays — people, machines, material waiting
  • I identify the constraint and confirm with WIP behavior
  • I validate throughput patterns against production targets
Day 2 — Quantify + Deliver
  • I confirm findings with your labor and downtime data
  • I quantify per-shift leakage in dollars
  • I build a prioritized recovery roadmap by financial impact
  • I deliver an executive readout — findings + next steps
What You Receive
  • Per-shift dollar leakage estimate (with assumptions sheet)
  • Prioritized recovery roadmap ranked by financial impact
  • Executive-ready slide deck
  • 30/60/90 day action plan
  • Finance-ready math: assumptions + sensitivity ranges
No Commitment Required

If You Stop After Phase 1

Phase 1 stands alone. You're not committed to anything beyond it.

You still leave with
  • Leakage math — per shift and annualized
  • Prioritized recovery roadmap
  • 30/60/90 day action plan

You can execute internally with your team, or bring me back for Phase 2 when you're ready. There's no expiration on the roadmap.

Floor Impact

How Disruptive Is This?

  • Observation-first — I'm not stopping lines
  • I work around your production schedule
  • Data requests are minimal and handled off-floor
  • I'm measuring how work actually moves — not running meetings
Phase 2

Rapid Operational Correction (4–8 Weeks)

Scope locked from Phase 1 findings. 1–2 outcomes only. Constraint first.

What Changes on Your Floor
  • Constraint stabilized and protected
  • Flow friction and backup points removed
  • Downtime reduced through root-cause corrections
  • Labor aligned to actual demand across the shift
How It's Managed
  • Scope locked from Phase 1 findings
  • 1–2 outcomes — no scope creep
  • Weekly cadence + scorecard agreed upfront
  • Before/after metrics tracked throughout
Outcome Measured leakage becomes recovered margin.
Phase 3

System Installation (6–12 Months)

Margin is recovered. Now I make sure it stays recovered.

What Gets Installed
  • Tiered daily management system (Tier 1–3)
  • KPI scorecards + operating cadence
  • Escalation rules
  • Standard work for 5–10 critical processes
  • Leader training routines
What This Prevents
  • Gains fading after engagement ends
  • Leaders reverting to reactive firefighting
  • Constraint drifting back without visibility
  • No single person holding the floor together
Outcome The floor runs on process — not on one person holding it together.
What I'm Watching For

The Measurement Checklist

  • Paid labor minutes not producing output
  • Constraint starvation and blockage patterns
  • Changeover loss and schedule adherence
  • Constraint utilization vs. planned
  • WIP stacking patterns
  • Overtime drivers and rework loops
Then I translate it into dollars: labor, overtime, missed output, expediting.
Common Questions

FAQs

Do we need an NDA?
Not required for the call. If you want one before sharing any production or labor data, I'll have it ready before you send anything.
What numbers do you need for the call?
Basic labor headcount, shift output targets vs. actuals, and a rough sense of downtime or overtime frequency. Nothing formal. I work with what you have.
Who needs to be involved internally?
One ops owner, one maintenance owner, and someone who can speak to scheduling/labor. I keep the circle small.
What if we already do Lean?
Lean tools and margin recovery are not the same thing. Many operations running Lean still have measurable leakage because the constraint isn't stabilized or the labor plan doesn't match actual demand. I start with the math, not the methodology.
What if we only want Phase 1?
Phase 1 is a complete standalone engagement. You receive leakage math, a prioritized roadmap, and a 30/60/90 plan. There's no obligation to continue.
How disruptive is Phase 1?
Minimal. I observe — I don't stop lines. I work around your production schedule and keep data requests off the floor. Most operators won't notice I'm there.
Do you work 2nd or 3rd shift?
Yes. If your leakage is happening on 2nd or 3rd shift, that's where I observe. I schedule around where the constraint actually runs.
How fast will we see impact in Phase 2?
Week 1 is constraint stabilization. Early indicators — throughput, overtime, downtime — typically move within the first two weeks. Meaningful impact is usually measurable by Week 4–6.
What I Guarantee

I guarantee the process: measurement, clarity, deliverables, and cadence.

No fluff. No endless decks. Just measurement, fixes, and cadence.

I don't guarantee a specific dollar amount — that depends on access, baseline stability, and execution speed.

Start Here

Know What's Leaking
Before the Next Shift.

20-minute call. I estimate exposure from your labor, output, and downtime numbers.

CALCULATE MY EXPOSURE See Services

If you're not a fit, I'll tell you on the call.