Alba Consulting - We Are Free !

Consulting services in ERP/MRPII systems, lean manufacturing and operations management.





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We are FREE!


Lean Manufacturing

Manufacturing Engineering

Interim Management

Quality Systems


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We are FREE!

Alba had, at one point, considered offering a No Fee service, whereby payment will be made as a percentage of savings achieved over a certain period, but decided that this arrangement would be very difficult to administer.  However, our primary focus is on achieving improved financial performance, so we are still open to relating our fees to actual improvements in your performance. After all, we are confident we’ll help you get those improvements.

However, we still like to think that Alba's services are effectively free, since we have a long history of cost reductions, waste elimination and productivity improvements, and Alba intends to continue this trend.  Your company should see a very quick return indeed, on any investment in seeking Alba's advice.

Here are some historical savings and improvements from Alba's assignments and also from the principal's own industrial career:

  • Manufacturing Engineering scrap and rework reduced from an annual figure of $180,000 to less than $10,000.  At same time shop scrap went from $1.5 million to $700,000.

  • Manufacturing Engineering head count reduced from staff of 60 to 45 with reduction to zero in late projects and while company sales were increasing.

  • As Operations Director, 2 years of losses changed to 4 years of consecutive and record profits.  Loss of $2 million changed to annual consecutive profits of $6 million, $8 million, $9.5 million and $9 million.

  • Overall Plant Productivity increased from 42% to 68%.

  • On time shipments improved from 34% to 92%.

  • Scrap and rework reduced from $800,000 to $120,000.

  • Saved $300,000 annually by setting up systems to allow company to have one inventory shut down per year instead of three.

  • Saved $600,000 annually on purchases by negotiating long-term agreements with vendors.

  • Manual change to automatic assembly line increased output by $120,000 per year.

  • Reduced inspection costs by 15% by training company in correct application of Acceptable Quality Level (AQL) sampling algorithm.

  • Company was about to lose 2 million dollar order due to unacceptable quality on injection molded components.  Meetings with supplier, tooling manufacturer and ourselves, identified the root cause and solved the problem.

These are just some of the improvements achieved in diverse industries such as machine tools, aircraft engines, electro hydraulic flight control systems, radar systems, computer components, travel trailers, sheet metal industries and medical components.  Company sales ranged from $10 million to $100 million.

We feel that our manufacturing and operations knowledge is as good as that of the large consulting organizations, and our fees are considerably less.  The principal, John Mannion, directs all the projects personally.  We feel that you will get a much bigger bang for your buck with Alba!


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