AC Manufacturing Solutions

Who this is for
Manufacturing and operations leaders facing inconsistent execution, tribal knowledge risk, throughput variability, or dependence on a few key individuals.

Core problem
Processes are not repeatable or clearly defined, limiting throughput, onboarding, and improvement.

What this engagement does

• Identifies process constraints and variability
• Converts undocumented knowledge into usable standards
• Establishes a stable baseline for future improvement

Typical deliverables

• Targeted process documentation (SOPs, SIPs, work instructions)
• Supporting CAD where ambiguity exists
• Process flow summaries
• Management-level stability and throughput assessment
• Prioritized improvement roadmap

What this is not

• Generic Lean training
• Full documentation of every operation
• Open-ended engineering support

Who this is for
Teams preparing to launch new products, scale production, or transfer work internally or between suppliers.

Core problem
Products or processes are technically complete but not ready for repeatable, predictable production.

What this engagement does

• Evaluates production readiness from a manufacturing perspective
• Identifies gaps between design intent and shop-floor reality
• Reduces risk before volume or transfer decisions are made

Typical deliverables

• Manufacturing readiness assessment
• Process definition and standardization
• Critical tooling or part CAD (as required)
• Work instructions for early-stage or unstable operations
• Risk register with mitigation actions

What this is not

• Design ownership
• NPI program management
• Prototype iteration services

Who this is for
Managers and directors who suspect hidden constraints, are missing output targets, or are considering overtime, outsourcing, or capital spend.

Core problem
Throughput is limited by poorly understood constraints rather than true capacity limits.

What this engagement does

• Identifies true bottlenecks and variability drivers
• Separates perception from data and observation
• Clarifies where improvement or investment actually matters

Typical deliverables

• Constraint and bottleneck analysis
• Cycle-time and variability assessment
• Capacity confidence summary
• Short-term and medium-term improvement options
• Decision-support summary for leadership

What this is not

• Time studies for their own sake
• ERP reconfiguration
• Continuous improvement task lists

Who this is for
Organizations with aging workforce risk, undocumented methods, or audit/quality/onboarding challenges.

Core problem
Critical manufacturing knowledge lives in people, not systems.

What this engagement does

• Captures and formalizes critical process knowledge
• Creates documentation that reflects reality, not theory
• Reduces operational risk tied to personnel dependency

Typical deliverables

• SOPs, SIPs, and work instructions for critical processes
• Supporting CAD or sketches where clarity is required
• Standardization plans aligned to actual execution
• Documentation hierarchy and governance guidance

What this is not

• Technical writing services
• Cosmetic document clean-up
• ISO/Lean checkbox documentation

Who this is for
Leaders considering automation, new equipment, or major process investment.

Core problem
Capital decisions are being made without a stable process baseline or clear ROI logic.

What this engagement does

• Assesses process suitability for automation
• Identifies prerequisites often ignored
• Reduces risk of premature or misaligned capital spend

Typical deliverables

• Automation readiness assessment
• Process stability gap analysis
• High-level feasibility and risk framing
• Recommendations on what to stabilize before investing

What this is not

• Machine specification or vendor selection
• Controls or programming services
• Turnkey automation projects