Operational Excellence Program Leads

Turn Your Production Floor into a Profit-Generating Machine

A proven system to eliminate waste, standardize operations, and increase profit margins

Juan Aldo Roos

Process Optimization Expert

Deon Beukes

Design & Manufacturing Specialist

Priit Veia

Senior SOP & Systems Engineer

Leading Cost Inefficiencies in Manufacturing

Most manufacturing companies are facing challenges, due to market competitors and economic pressure, these challenges become more critical. This threaten their profitability and long-term survival:

Operational Inefficiency

57% of manufacturing/production processes contain non-value-adding activities that directly reduce profit margins

Employee Onboarding Struggles

New hires take an average of 6-9 months to reach full productivity in specialized manufacturing roles, which threatens ROI

Knowledge Silos

Average SME's hold 73% of critical operational knowledge in employees eligible for retirement within the next 5 years

Quality Inconsistency

Manufacturing defects and rework cost the average Manufacturer 15-22% of anual OPEX budget

Cost Tracking

SME's attest 20% of development cost to losses due to lack of First Time Right systems

Risk Management

15% of Start up companies are not competative on market entry due to lack of proper Risk management and Failure Mode Effect Analysis

The Real Cost to Your Business:

For a typical Engineering component manufacturer doing $10M in annual revenue, these inefficiencies translate to:

$1.5-2.2M in annual waste and rework costs
$500K+ in productivity losses from slow employee onboarding
Risk of knowledge loss with each retiring employee
Operational inefficiencies causing losses of up to 2% in annual growth

Implementation: BRV Operational Excellence Program

Our comprehensive solution transforms your manufacturing operations through world-class Standard Operating Procedures (SOPs) and systems that eliminate waste, capture institutional knowledge, and drive profitability.

1

Proprietary Process Mapping & Value Stream Analysis

We identify every Non-Value-Adding Activity in your operation and develop elimination strategies that can be implemented immediately

2

Rapid Onboarding Acceleration System

Cut new employee ramp-up time from 6-9 months to just 5-6 weeks with our proven training integration methodology

3

Intercompany Knowledge Transfer system

Built-in mechanisms to capture knowledge and establish a sustainable growth system

4

Industrialization - SOP & WOW Development

Our aerospace-grade documentation system transforms tribal knowledge into clear, visual SOPs that reduce errors by up to 87%

5

FTR structure introduction

Design & Process Validation and cross-departmental integration strategy implementation

6

Risk Management System Introduction

Process Risk Analysis and mitigation system establishment - FMEA

What Makes Our Approach Different:

Unlike generic consultants, our team brings direct experience from Meta, ASML, Rheinmetall and other world-leading manufacturers. We've implemented these exact systems for EUV lithography equipment (precision manufacturing), AR/VR Optics development and Energy pack Industrialization lines.

Operational Excellence Program

Our Proven 8-Week Implementation Process

1

Deep-Dive Discovery [Define](Week 1)

Our team conducts a comprehensive analysis of your current manufacturing processes, identifying all bottlenecks and waste points

2

Value Stream & Process Mapping [Measure](Week 2)

Complete documentation of your value stream and process with quantified waste elimination opportunities

3

SOP & WOW Framework Development [Analyse](Weeks 3-4)

Creation of your Standard Operating Procedures with visual aids, troubleshooting guides, according to optimal Way of Working

4

Core Process Documentation [Improve](Weeks 4-6)

Development of 15-20 critical Work Instructions/Technical Product Documentation for your highest-value and highest-risk processes

5

Training & Implementation of Control System [Control](Weeks 6-7)

Team training on SOP usage, first line maintenance planning, and continuous improvement methodology

6

Verification & Refinement [Validation](Week 8)

Live testing of SOPs with measurement of defect reduction and efficiency improvements

The Operational Excellence Program in Action

Case study 1: Large International Company, Manufacturing in Europe

When Aldo implemented similar SOP systems for a leading optics manufacturer:

Cut new operator training time from 8 weeks to just 4 weeks, with introduction of structured training program and buddy system
Reduced manufacturing defects by 34% in the first 60 days, with Risk managemnet and FMEA execution
Increased production throughput by 18% with the same headcount, through introduction of process improvement, process optimization and bottleneck mitigation
Standardized production Way of Working across international facilities

The result: Successful production of 40,000 precision optical units in just 4 months with a team of 17 operators, decreasing overall time to market by 1 months.

Case Study 2: Medium Munitions Manufacturer in Africa

When Deon implemented Equipment Improvements at a Leading Munitions Manufacturer:

Achieved 20% production increase while reducing costs by 10%
Reduced Non-Value Adding Activities throughout the production process
Reduced quality issues through error-proofed procedures

34%

Avg. Defect Reduction

300%

ROI in First Year

50%

Faster Onboarding

Results Guaranteed - 100% Payment on Final Acceptance

Next Steps: Book Your No Obligation Assessment

Schedule a 90-minute assessment, where we'll dicuss your biggest efficiency improvement opportunities and outline how our program would benefit your operation.

Schedule Your Assessment Now

Contact: Aldo Juan Roos | ajroos@brv-eng.com | (+31) 68 5091 805