01On-Floor Execution for Manufacturing

We turn variability
into throughput.

Sprauve Consulting delivers hands-on implementation that stabilizes operations, tightens daily execution, and produces results that hold after we leave.

Yellow drive guard on a case conveyor in a high-speed beverage plant
Case conveyor drive, high-speed beverage line© Sprauve Consulting
Founder
Osiris Sprauve, MBA
Background
Former plant GM, Fortune 100 beverage
Sector focus
Beverage & CPG manufacturing
Engagement model
Embedded practitioner on your floor

Selected results from completed engagements

45%+

efficiency improvement on high-volume beverage lines

63%+

volume increase within weeks of an on-floor execution reset

Top 3

network performance ranking achieved at multiple sites

Industries we serveBeverage manufacturingCPG & food productionPackagingHigh-speed consumer manufacturing
Match-marked guide rail with a steel rule on a high-speed can line

Where the work happens

Performance is won or lost on the line, on the shift — not in the conference room.

Not analysis for analysis' sake.

The focus is locking in execution through clear standards, tight routines, and supervisors who can run the system without external support. We work side-by-side with manufacturing teams to stabilize operations where performance actually breaks down — on the floor, on the shift, and at key handoff points.

Diagnose, then implement.

Most engagements unfold in two phases. A short, structured gap assessment sets the baseline and surfaces the highest-impact gaps. The implementation work that follows is where performance actually moves.

Phase 1 · Diagnose

Two on-site assessments.

Two independent diagnostics — run either on its own, or both together (each with its own team). Pick the one that maps to where performance is breaking down.

D1
Operational

Production System Assessment

Production system diagnostic · 4 days on site

A structured, on-site diagnostic of the production system: an end-to-end value stream walk paired with a critique across the seven Production Fundamentals. Operator-validated, leadership-actionable — and the agenda for the implementation work that follows.

Outputs
  • Value stream map (depalletizer → palletizer)
  • Production Fundamentals scorecard
  • Leaky-pipe observation log
  • Quick-win action register
  • Scoping for MOS / centerlining work
Operator in a hard hat working at a roller conveyor during a line walk
Line walk, roller conveyor
D2
Reliability

Maintenance & Reliability Assessment

12-pillar maturity scoring · 4 days on site

A structured 1–5 maturity scoring across twelve reliability pillars, benchmarked against current best practice. Ratings are triangulated across interviews, floor observation, and document review — then delivered as an executive readout with a prioritized roadmap.

Pillars assessed
  • Strategy & Leadership
  • Work Management · CMMS
  • PM & PdM Programs
  • Planning, Scheduling & Execution
  • MRO / Storeroom
  • Reliability Engineering
  • Safety & Compliance
Hands cleaning and inspecting conveyor rollers
Clean, inspect, lubricate on a roller conveyor

How we score

When we score a gap and are torn between two answers, we choose the lower. An assessment is meant to surface gaps, not flatter performance — and the trust we build starts there.

Phase 2 · Implement

Where the work actually happens.

Scoped from the assessments and run with a seasoned practitioner embedded on your floor.

Operational trackScoped from the Production System Assessment · run together as one engagement
i.

Management Operating System & Focused Improvement

8 – 16 weeks · supervisor-led, floor-validated

The daily cadence that turns improvement into a habit, paired with structured work on chronic losses. Built so supervisors run the floor without escalation fatigue — and so the system outlives the person who first stood it up.

Built & sustained
  • Leader standard work
  • Tiered huddles & SIC
  • KPI scoreboard & review cadence
  • Loss-tree analysis & RCA on top losses
  • Daily follow-up & on-shift coaching
Hour-by-hour production board at the line: hours above standard rate in green, below in red, downtime and notes in black
Hour-by-hour board at the line · green above rate, red below, deviations in black · entries obscured
ii.

Centerlining

8 – 16 weeks · line-by-line

A full centerline program built end-to-end, line by line. The result: stable, repeatable equipment settings that hold across shifts and SKUs.

Focus areas
  • 10-step centerline program
  • Operator-led CIL standards
  • Adj.-point ID, elim. & fix-in-place
  • Match-marking & setpoint control
  • Sustainability & re-assessment
Guide rails with steel rules and painted match-marks on a can line
Match-marked guide-rail setpoints, can line
Reliability trackScoped from the Maintenance & Reliability Assessment · stands on its own
iii.

Maintenance & Reliability Program Implementation

16 – 24 weeks · full-stack reliability

A full-stack reliability build, scoped directly out of the M&R assessment. Moves a reactive maintenance organization to a managed, data-driven one that sustains itself.

Tracks
  • PM & PdM program optimization
  • CMMS data integrity
  • Planning & scheduling discipline
  • MRO / storeroom restructure
  • Reliability engineering build
Standards, checklists and escalation procedures posted on a board at the line
Standards and escalation procedures posted at the line · document detail obscured

The work happens on the floor.

Three commitments shape every engagement. They are the things we have already decided so you don't need to ask us to decide them in the moment.

i.

On the shift, not in the conference room.

An embedded practitioner works alongside your operators, supervisors, planners, and mechanics — on the floor, on the line, on the same shift. Findings are not surprises to the people who live them; they are observations leadership can finally respond to.

ii.

Standards, not slides.

We leave behind operating windows, leader routines, KPI cadences, and the supporting standard work — built with your team, owned by your team. The output is a system, not a deck.

iii.

It has to hold after we leave.

Every routine we build is designed to be sustained by the people who first ran it. Where capability is missing, we coach and train until the supervisor can run it without us — and then we step back.

A sample from each diagnostic.

Two samples — one drawn from each assessment, on a high-speed beverage floor. Each shows the shape of the work, not the full engagement.

Production System Assessment

Value stream mapping · 7 Production Fundamentals critique

Value stream mapping board built on the floor during a Production System Assessment — illustrative sample, detail intentionally obscured
From a real engagement — board detail obscured and client identity withheld for confidentiality.© Sprauve Consulting

Sample engagement

High-speed beverage plant

An end-to-end value stream walk paired with a Production Fundamentals critique — operator-validated and leadership-actionable, delivered as a day-four scoping report-out.

Engagement type
Production System Assessment Phase 1 diagnostic
Duration
4 days on site Day-four scoping report-out
Focus
Depalletizer → palletizer Full line, all shifts
Output
Quick-win register Scoped MOS & centerlining

Maintenance & Reliability Assessment

12-pillar maturity scoring · benchmarked against best practice

Maintenance & Reliability executive readout: 12-pillar category scorecard with an overall maturity score of 2.05 — illustrative sample
From a real engagement — figures shown with client identity withheld for confidentiality.© Sprauve Consulting

Sample engagement

High-speed beverage plant

A structured maturity assessment across the twelve reliability pillars, delivered as an executive readout on day four — with a prioritized recommendation roadmap and quick wins.

Engagement type
M&R Assessment Phase 1 diagnostic
Duration
4 days on site Day-four executive readout
Sector
High-speed beverage Production & distribution
Output
Roadmap + quick wins Scoped Phase 2 implementation

A small firm, by design.

Most of the large firms in this space will sell you a thick deck and a junior team learning on your floor. We are deliberately a different shape — a seasoned practitioner doing the work alongside your team.

Most large firms

Sprauve Consulting

A partner sells, an analyst delivers.

A seasoned practitioner embedded on your floor — not an associate learning on your dime.

Eight-week diagnostic, six-month bench.

A focused on-site diagnostic — momentum in week one, not month three.

Recommendations leave with the team.

Standards, routines & KPIs your team owns.

Conference-room work product.

Floor-validated by operators across every shift.

Capital-spend recommendations.

Most gaps are recoverable through routines — not spend.

Proven results, in their own words.

Excerpts from leaders at beverage and bottling clients we've partnered with. Identities held in confidence.

We're coming off our strongest month yet — and some days of all green.

VP, Product SupplyBeverage Manufacturer

You helped us get traction we've never been able to achieve.

Plant DirectorMulti-Line Bottling Facility

We saw rapid improvement at sites where we'd historically struggled. Your on-floor approach strengthened supervisors, tightened routines, and helped drive more predictable operations.

SVP, Product SupplyNational Bottling Network

Two decades on the plant floor.

Twenty years of plant-floor leadership — earned in operating roles inside a Fortune 100 beverage network — brought to the manufacturers who need it most, in the language they already work in.

Selected results from prior plant roles.

$100M+
P&L

Plant General Manager of a flagship juice manufacturing facility, with full operating and capital responsibility.

5 yrs +
Zero lost-time accidents

Sustained safety culture across a 24/7, multi-line beverage operation — with a 2017 AIB food-safety score of 910.

#1
Profit Plant of the Year

2015 — fifth of sixty-nine plants in the network. Also: first plant in the network to pass TPM Phase 2.

40M
Cases / year

Earlier in career: Operations Manager of a high-speed beverage production and distribution facility with a $32M operating budget.

4.35M
CPC improvement

Year-over-year usage CPC improvement as National Profit Sub-Team Lead — Yield Top Ten & Routines.

14 yrs
Inside a Fortune 100 beverage company

Plant operations through North America Contract Manufacturing — leading partner relationships, contracts, and on-site execution.

The firm brings that same operating posture to plants that haven't had it. The work is not analysis for analysis' sake — it is locking in execution.

Credentials
MBA · Supply Chain Leadership & Lean Manufacturing
Methodologies
Six Sigma · TPM · Lean Manufacturing · VPP Gold Standard Safety

Questions we hear in the first call.

Most prospects ask a version of these in the first fifteen minutes. The answers below are the same ones we give there.

i.Who actually shows up on site?
A seasoned practitioner with real plant-floor leadership experience, embedded on your floor for the duration. The right practitioner is matched to the engagement type — MOS work, centerlining, or maintenance & reliability. Never a junior associate learning on your dime.
ii.How long is a typical engagement?
A gap assessment is four days on site, with the executive readout delivered on day four. MOS / supervisor-routine work typically runs eight to sixteen weeks of on-site cadence. Centerlining & downtime attack runs eight to sixteen weeks. Maintenance & Reliability program builds typically run sixteen to twenty-four weeks. Ongoing follow-up is available on retainer.
iii.Where do you work?
On site, nationwide — we travel to your facility for the time we're with you. Multi-site network engagements are routine.
iv.What do we walk away with?
For an assessment: an executive readout deck with maturity scores across twelve pillars, a prioritized recommendation roadmap, and a quick-wins register. For execution work: documented standards, leader routines, a KPI scoreboard, and supervisors trained to run the system in our absence.
v.Is this a report-and-leave engagement, or do you stay?
Either, by design. Some clients want only the diagnostic and choose to execute internally. Most ask us to stay through the first phase of implementation so the routines lock in before we step back. We never aim to embed permanently.
vi.What does it cost?
Fees scale with engagement length and site complexity. We quote per scope rather than per hour, so you know the number before we start. Start with a fifteen-minute call — we will give you a directional range before you commit to anything.

Close the gap between your best shift and your worst.

Start with a 15-minute conversation — no pitch, just a diagnostic. Tell us what's breaking down, and we'll tell you what we'd look at first.

Principal
Osiris Sprauve, MBA
Email
Phone
LinkedIn
Office
7025 County Rd #46A
Ste 1071, Unit 155
Lake Mary, FL 32746

Sprauve Consulting, LLC.
On-floor execution for manufacturing.