- Angle
Name the number, then earn the install.
- Brief
The manufacturing operational-improvement brief: a precision manufacturer wants to scale processes, establish KPI ownership on the shop floor and prepare the plant for an automation rollout.
- Measurement and next step
Track the three things the brief cares about: whether the chosen metric moved against its baseline, whether problems are being raised and closed faster at the huddle, and whether frontline staff can describe what changes in their jobs when the automation arrives.
Before signing, ask for recent results from a comparable manufacturing, KPI or automation engagement and the actual The Fabricator article Zurborg says covers what worked and what did not in the Skilcraft automation programme.
A first paid session is a reasonable next step: one working session to select the starting metric and set the baseline. Scope phases 2 to 4 only after the session confirms the operation has data and someone to own the number.
- What the manufacturer must supply
Twelve months of quality data covering scrap, returns and rework, so the baseline is real rather than estimated.
An operations or quality lead to own the metric between sessions, and permission for shop-floor staff to raise problems in a weekly huddle.
Access to the plant floor, including at least one walkthrough with the people doing the work. The value here lies in observed process detail, not slide decks.
Agree in advance on how results will be judged. Ask for evidence to support the outcomes described in Zurborg's posts, which the posts do not independently verify.
Decide the engagement type up front: coaching or consulting, rather than sponsorship, since no sponsorship terms are documented.
- Why it works
The plan draws on two things Zurborg's posts demonstrate firsthand: setting a shop-floor quality metric people own, and treating automation adoption as a culture and communication problem rather than an equipment problem. It orders them to match the manufacturer's constraint: measurement first, then automation.
- Worked plan
Phase 1 — Pick one number. In a working session with the owner, operations lead and quality manager, choose one quality metric to start with, from the same family Zurborg describes tracking: in-process scrap, customer returns or rework rate. Define the current baseline and set a target consistent with the top decile of the industry rather than an internal best-ever. Deliverable: one page listing the metric, baseline, target, owner and review cadence.
Phase 2 — Give everyone a number. Extend the chosen metric to each production employee, each department and the company as a whole, following the structure described in the KPI post. Create a visible metric board and hold a weekly problem-solving huddle where the people closest to the process raise issues. Success means identifying problems faster and solving them sooner, not building a dashboard.
Phase 3 — Audit one inherited assumption. Run the $5-fee exercise on the manufacturer's own operation: pick one long-standing practice nobody has revisited, usually a pricing, quoting, programming or handling step that has quietly scaled with volume, and quantify the change. Zurborg's published example is a processing fee for software-key programming that reportedly added $50,000 without a new product. The aim is to show the team that small process changes pay.
Phase 4 — Prepare the automation rollout as a people project. Before specifying equipment, hold frontline sessions on what changes in each person's job, who operates what, what the new work looks like day to day and what input staff have on the choice. The automation post's design principle: when the team was involved from the start, the equipment became a source of pride; when they were not, it sat unused. Pair this with DiSC/TTI assessment work if the rollout requires new roles or reassigned seats.
Phase 5 — Hand off to a peer group or a continuing coaching cadence. If the owner wants accountability from other owners rather than more one-to-one sessions, the confidential round-table format Zurborg moderates—bringing together leaders across finance, technology, nonprofit and professional services—is a natural continuation.