Plants run better when the system does.
North Plant Consulting brings Toyota Production System discipline to manufacturing plants — production control, standardized work, daily management, and the visual systems that make on-time delivery hold.
Request a Consultation Explore ServicesSeven capabilities that make a plant deliver.
Hands-on operations consulting for manufacturers — grounded in the Toyota Production System and focused on measurable improvement, not binders on a shelf.
Operational Assessment
A structured on-site review of flow, scheduling, staffing, data, and daily management — showing exactly where your plant loses time and money, with a prioritized improvement roadmap.
Production Control & Scheduling
Constraint-based master scheduling, order launch and release rules, and real-time order visibility — so every department knows what to deliver, in what sequence, by when.
Process Data Capture
The shop-floor data most plants never collect — cycle times, miss reasons, order aging, downtime causes — captured simply and reliably, so decisions run on facts instead of anecdotes.
Dashboards & Real-Time Visibility
Where every order sits, which department holds it, and how long it's been there — live plant dashboards and hour-by-hour boards the whole floor can see and act on.
KPI Systems & Accountability
Metric definitions everyone agrees on — OTD, first-pass yield, productivity per labour hour — with cascaded objectives and tiered daily management that turn numbers into ownership.
Org Design & Capacity Planning
Floor org charts with defined spans of control, job descriptions rebuilt against real work, headcount models tied to demand, and skills matrices so cross-coverage is planned — not improvised.
Training, SOPs & Standard Work
Standardized work for every core job, TWI-style train-the-trainer programs, tiered operator certification with visible tracking, and hazard analysis built into every SOP.
What your floor looks like when the system runs it.
Not stock photos — the actual tools we build with your team: hour-by-hour boards, standardized work, and a daily management cadence that escalates problems in hours, not weeks.
| Hour | Plan | Actual | Status / Reason |
|---|---|---|---|
| 7–8 | 12 | 12 | On plan |
| 8–9 | 12 | 13 | +1 ahead |
| 9–10 | 12 | 8 | Kitting short — R04 |
| 10–11 | 12 | 12 | Recovered |
| 11–12 | 12 | 12 | On plan |
Every miss gets a reason code the moment it happens — so "why did it miss" produces data, not arguments.
One best way, written down — quality checkpoints and safety callouts built into the sequence, TWI-style.
A standing cadence with a defined escalation path, so nothing waits for the monthly meeting to get unstuck.
Toyota discipline, applied to your floor.
North Plant Consulting is built on Toyota Production System experience — standardized work, TWI-style job instruction, tiered daily management, and visual control, applied hands-on in real plants, not taught from a slide deck.
Our approach is system-first: when delivery slips or a department is drowning, the root cause is usually a missing process, not a missing person. We fix the system, then build the roles, training, and cadence that keep it running after we leave.
Talk to UsWhy clients choose us
- Toyota Production System & TWI background — methods proven for decades
- System-first: fix the process before touching the org chart
- Measurable results: on-time delivery, first-pass yield, productivity per labour hour
- Built to sustain — your supervisors and leads run it after we're gone
A straightforward engagement process.
Listen
A no-cost intro call to understand your operation, your pain points, and what success looks like.
Assess
On-site or remote review of your operations, data, and processes to find the biggest opportunities.
Plan
A prioritized, practical improvement plan with clear owners, timelines, and expected impact.
Deliver
We stay engaged through implementation so improvements stick — and results show up in your numbers.
Let's talk about your plant.
Tell us a bit about your operation and the challenge you're facing. We'll follow up within one business day.