BICKERDYKEMANUFACTURING ADVISORY
Manufacturing problem solving · Houston & Georgia

The problem that keeps coming back has a cause. I find it.

Fifty-five years on the shop floor, from a machinist’s apprenticeship to running plants and their ERP systems. I help small and mid-sized manufacturers fix the scrap, setups, late jobs and cost overruns that everyone has learned to live with.

Email me about your problem Call (832) 874-1234
JOB TRAVELERPart 4471-B · Qty 250
OPOPERATIONROUTED HRSACTUAL
10Saw cut1.51.6
20CNC turn – setup1.03.8
30CNC mill6.26.5
40Deburr & inspect2.02.3
?The routing says one hour, every time. The floor says nearly four. Is it the fixture, the tooling, the program, or the standard? That gap is where I start.
Example for illustration
Approach

Most problems cross three places. Most people only look in one.

A machinist sees the machine. A manager sees the schedule. The ERP team sees the data. I’ve done all three jobs, so I follow the problem wherever it goes.

AT THE MACHINE

Method

Setup, tooling, workholding, operation sequence, the CNC program and cycle time. What the operator actually does, compared with what everyone thinks they do.

ACROSS THE PLANT

Flow

Bottlenecks, queues, handoffs, rework loops and inspection. Where jobs wait, where they come back and where the work gets done differently from shift to shift.

IN THE SYSTEM

Data

Routings, standards, BOMs, labor reporting and job cost. Why the ERP says a job made money when the floor knows it didn’t.

Where I’d start

Pick the problem you’re living with.

Here is the first question I’d ask, and the first places I’d look.

FIRST QUESTION

At the machine

    Across the plant

      In the system

        Services

        Small, defined pieces of work. No long contracts.

        You don’t need another full-time hire. You need the problem solved and the fix to hold.

        Start here

        Manufacturing Problem Diagnostic

        One problem that keeps coming back. I look at it on the floor and in your data, talk to the people doing the work, and give you a short written report with the likely root causes and what to fix first.

        SCOPEOne agreed problem, one part family or one process
        TIMEA fixed number of days, agreed before we start
        YOU GETRoot causes, prioritized corrective actions, and a way to measure the result
        THENFix it yourselves, or I help you implement and verify

        CNC & Machining Process Review

        Machine choice, operation sequence, setup, tooling, workholding, programs, inspection and cycle time.

        Routing, Standards & Job Cost Review

        Quoted against actual for material, setup, labor, secondary operations and scrap, and where the ERP disagrees with the floor.

        Continuous Improvement Review

        Follow a process end to end to find waste, bottlenecks, rework, poor handoffs and weak controls.

        Implementation Support

        Assign the actions, test the changes, measure the result and make the better method the standard one.

        Manufacturing Advisor

        A few hours a month as an outside set of eyes for an owner or plant manager.

        Training, Mentoring & Second Opinions

        Practical sessions for supervisors, programmers and planners, or an independent check before a big machine, CAM, ERP or sourcing decision.

        How it works

        Routed like a job.

        OP 10

        Talk

        You describe the problem. I ask how long, how often, and what changed.

        OP 20

        Observe

        On the floor with your people, then the drawings, routings, programs and job history.

        OP 30

        Report

        Symptoms separated from causes. A short list of practical changes, in order.

        OP 40

        Verify

        We measure whether the fix holds. If it doesn’t, we go back to Op 20.

        Background

        I started on the tools at fifteen.

        A five-year indentured apprenticeship, then a career making metal and plastic parts in small and large quantities, on manual lathes, mills and grinders, legacy machines and CNC. Later I moved into management and manufacturing engineering, and into the systems that run the business.

        1. Lucas Aerospace, UKFive-year indentured machinist apprenticeship
        2. Deighton Manufacturing, BradfordFood machinery and components
        3. Harley-Davidson, MilwaukeeMotorcycle parts
        4. Houston, 20+ yearsOil and gas components and assemblies
        5. Cable and interconnectManufacturing engineering and works management
        55+years in manufacturing, at the shop-floor level
        CNCmachining and programming, including extensive Edgecam
        Mgmtmanufacturing and works management
        Enghired as a Manufacturing Engineer for breadth of knowledge
        Business systems: Microsoft Dynamics 365 (long-term), Epicor 10.2, and Oracle through the Dover migration.
        Contact

        What problem keeps coming back?

        Call or email with a short description. If I can help, I’ll tell you how I’d approach it. If I can’t, I’ll tell you that too.

        Email David Call (832) 874-1234 WhatsApp LinkedIn
        David Bickerdyke
        Principal, Bickerdyke Manufacturing Advisory
        SERVING
        Houston, Atlanta & Georgia