Outcome LLC | David E. Jones | Operational Turnaround

RESULTS

// Audited results. Not projections.

THE NUMBERS DON'T LIE

4% → 93%

Overall Equipment Effectiveness

Client T — steel-tube maker. A dead plant everyone said couldn't be saved.

15 months

2% → 98%

First Time Quality

Client M-S-J — auto assembly, Japan. A failing operation turned into the most profitable global unit.

3 weeks

$80M+

Annual Cost Reduction

Client N — auto OEM, North America. 6M sq ft, 6 vehicle models, 400 AGVs.

Annual target: $100M

Output Per Person

Client G — digital manufacturing. World's largest connected 3D-print farm; 5 to 35 units per person per day.

5 months

BREAK-EVEN

Restored

Client B-L — building products. Years of losses reversed; a machine running in 3 weeks after 8 years down.

3 months

SOFTWARE

// The discipline, now in software

SQPC — YOUR FLOOR, CLOSED-LOOP

Every shift, your team tracks Safety, Quality, Productivity, and Cost on one board. When something goes red, SQPC doesn't just log it — it opens the A3. Root cause, countermeasure, done. The problem-solving gets captured, so the knowledge outlives the people who have it.

S·Q·P·C

One daily board. Red / yellow / green, by shift and by line — the floor's condition at a glance.

→ A3

Abnormalities open themselves. A defect or a missed target auto-drafts an A3, pre-filled and ready to solve.

∞

Knowledge compounds. Every solved problem stays — a floor that teaches the next person instead of retiring with the last one.

Request Founding-Beta Access

Early access · free onboarding · no card

Daily SQPC — Line 31st shift

Safety

Quality · FTQ

96%

Productivity

94%

Cost · scrap

↑

Cost went red → SQPC drafted A3 #0442 → your team fills root cause & countermeasure

PORTFOLIO

// Real work. Not renderings.

FROM THE FLOOR

Client B-L

Years of losses → Break-even in 3 months

Building products manufacturer. No standard work, no flow, no visual management. Assembly chaos with parts in cardboard boxes on the floor. Restarted a machine that had been down 8 years. Designed aluminum extrusion workstations with organized parts presentation and ergonomic tooling.

Before

Assembly area. Parts in cardboard on the floor. No flow. No standard work. No visual management.

After

Same area. Aluminum extrusion workstation. Labeled bins. Spring balancers. Every part has a home.

Client T

4% → 93.9% OEE in 15 months

Family-owned steel tube manufacturer. First outside operator in company history. Built OEE monitoring, jidoka culture, and a custom $39K inline inspection system (74% below industry standard). Hired and developed the quality manager and maintenance manager from scratch.

Vorne XL HD display showing DOWN state - red screen, 0 actual output, 5+ hours downtime

Vorne XL HD — DOWN. Red screen. 0 actual. 5:29 downtime. 19,781 target. This is what the truth looks like when you first turn the lights on.

Vorne XL HD display showing RUNNING state - green, 4856 actual, 103.8% efficiency

Vorne XL HD — RUNNING. Line 16. 4,856 actual. 103.8% efficiency. 95.8% availability. 97.2% quality. Same plant.

Vorne andon dashboard showing plant-wide OEE monitoring across 5 machines

Plant-wide andon. All machines at a glance. RS 40 Mill, BEWO Saw, Haven 2–4. Running customer parts. Real-time visibility.

Custom inline coil inspection system with Keyence laser sensors on tube forming press

Custom inline inspection. Keyence laser sensors measuring coil thickness & width at 300m/min. My concept, $39K build vs $150K off-the-shelf. Jidoka — catch it at the source.

Stop-Call-Wait quality sign - Ensure Quality! Stop when you see a defect, Call for support, Wait before proceeding

Stop–Call–Wait. I created this at a plant that had never had quality culture. STOP when you see a defect. CALL for support. WAIT before proceeding. Pure TPS.

David Jones with his team members on the factory floor

The team I built. Daniel (green, visiting customer — a Tier-1 seating supplier). Royce (yellow, quality manager I hired). Chase (orange, maintenance manager — came in as a TCAT student in 2016, now runs maintenance).

US Senator Bill Hagerty examining steel tube product during facility visit

U.S. Senator Bill Hagerty visits. His office chose us for a Go and See workforce visit. The link: he served as U.S. Ambassador to Japan, I spent 11 years at Toyota in Japan. His team thought that connection was worth seeing firsthand.

Client M-S-J

2% → 98% First Time Quality in 3 weeks

Turned the client's failing Japan operation into their most profitable global unit. Applied the real Toyota Production System — not the textbook version — to transform quality and throughput.

Yamazumi board with colored magnets showing work element allocation in Japanese

山積み表 — Yamazumi board. Color-coded work elements mapping human and machine cycle time. All in Japanese. This is how Toyota actually designs production lines. I read it, I write it, I teach it.

METHOD

// How it works

NO MYSTERY. JUST METHOD.

We Walk Your Floor

Not your conference room. Your floor. Where the work happens. Watching. Measuring. Asking "why" until we find root cause. Week 1.

We Find the Gap

Between where you are and where you should be. Not feelings. Not opinions. OEE. FTQ. Takt time. Throughput. Measured. Documented.

We Close It

With your team. On your floor. Teaching them to see what we see. Building systems that stick. Weeks 2–10.

We Leave

And it keeps working. Because your people own it now. This isn't magic. It's method. They'll carry it forward without us.

PHILOSOPHY

// Learned in Toyota City, Japan. Not from a book.

WHAT WE BELIEVE

Ideal Condition Exists

Every process has one. Most companies have never defined it. We learned this from the people who invented the Toyota Production System — on the floor at Tsutsumi, Motomachi, Tahara, and Kyushu.

The Gap Is Measurable

Not feelings. Not opinions. Data. OEE. FTQ. Takt time. Throughput. If you can't measure it, you can't close it.

Closing It Is Work

Real work. On the floor. With your people. Not in conference rooms. Not on Zoom. Not "advising." Doing.

Your People Own It

We teach your team to see. When we leave, the system stays. That's the difference between a consultant and a sensei.

FIT

// Honest about who we work with

IS THIS FOR YOU?

This Is for You

You're bleeding money on your production floor and you don't know why

You bought automation that was supposed to fix everything. It didn't.

You're cutting headcount but output is dropping faster than labor costs

Your "lean program" produced posters, not results

You need someone who's done this before. Fast. No ramp-up time.

This Isn't for You

You want a consultant who tells you what you want to hear

You want more reports, not more output

You're not willing to change how work gets done

You think manufacturing excellence is a slogan

ABOUT

// 30 years making factories work

WHO WE ARE

Trained in Toyota City, Japan. 11 years learning the real production system from the people who built it. Not from books. Not from seminars. From the floor.

Business-level Japanese. 17 years living in Japan. Permanent resident. We bridge the gap between Western manufacturing and the culture that created TPS.

Machinist. Supervisor. Plant manager. VP. We don't advise from conference rooms. We're on the floor until it's fixed.

Based in Nashville, Tennessee. Will travel anywhere the work is.

Toyota Vehicle production engineering. 4 plants. 11 years in Japan.
Client N 6M sq ft. 6 models. 400 AGVs. $80M+ savings.
Client M-S-J Turned failing Japan unit into most profitable globally.
Client C Scaled EV battery production. Prototype → 1,000+ units.
Client G World's largest 3D print farm. 5 → 35 units per person per day.

JAPAN ↔ US

// Bringing Japanese manufacturers into America — without the system getting lost in translation

THE BRIDGE

Japanese manufacturers entering the US rarely fail on the technology. They fail on the operating culture — how decisions get made, how quality is defended, how the floor is run. That gap doesn't translate cleanly across the Pacific.

That's 16 years on the Asia side of that gap — 14 in Japan, permanent resident, business-level Japanese — and 30 years building factories on both shores. We don't translate the words. We translate the system.

CURRENTLY

Head of US Business Development

a Japanese wireless-power (WPT) startup

Leading US market entry for an early-stage Japanese technology company — go-to-market strategy, OEM and logistics-partner targeting, and TPS-grade operational rigor brought to a scaling hardware business.

01US market-entry strategy & go-to-market for Japanese manufacturers

02OEM & supplier relationships built in both languages, both cultures

03Localizing the production system — not just the org chart

ENGAGEMENT

// The deal

HOW WE WORK TOGETHER

88 Days

That's the engagement. Proof of concept. Measurable results. Then we decide together what comes next.

Measurable Targets

Agreed upfront. OEE, FTQ, throughput, cost per unit. Not vibes. Numbers.

On Your Floor

Not on Zoom. Not "advising." Doing. With your people. Where the work happens.

Your Team Learns

This isn't magic. It's method. They'll own it when we leave. That's the whole point.

MISSION

// Why we're building this

THE KNOWLEDGE IS RETIRING.
WE'RE ENCODING IT BEFORE IT GOES.

The people who learned it right — inside Toyota, on real floors — are retiring, and the training that should pass down isn't. Too many plants jump straight from product to equipment, skip the manufacturing engineering, and build lines that never quite run. We take that discipline — the Toyota Production System way of thinking — and encode it into software that teaches the next generation, fast. Because the knowledge shouldn't retire with the people who have it.

FIND THE
IDEAL CONDITION. MAP THE GAP. CLOSE IT.

THE NUMBERS DON'T LIE

SQPC — YOUR FLOOR, CLOSED-LOOP