Better. Faster. Cheaper.
Make work obvious. Make performance repeatable.
Costs down. Quality up.
Boiler Agency helps manufacturers stabilize production, reduce scrap and downtime, and improve buildability—using Lean Six Sigma, Project Management methodology, and disciplined execution on the floor.
Inline improvements first. Downtime only when it’s truly justified—and scoped, scheduled, and controlled.
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JAMES OLIVER
Proven across diverse manufacturing
Examples, not limits—if you build it, we can improve it
Electronics & Avionics
Electronics builds, harnessing, test/rework, RF/ESD realities
Robotics & Automation
Cells, handoffs, sensors/vision, and mistake-proofing
Plastics & Molding
Injection molding + downstream assembly/packaging flow
Fabrication & Sheet Metal
Fab, fixtures, workcells, layout and flow
Reliability & Test
Environmental chambers, verification, failure-mode cleanup
ISO Quality Systems
ISO 9001 / ISO 13485 environments; operate within EHS constraints
Find the right starting point
Production Stabilization
When output isn’t predictable
We stabilize the line using standard work, visual management, and daily accountability. Downtime gets defined, categorized, and eliminated. Performance becomes repeatable—without defaulting to shutdowns.
Bottleneck to Flow
When lead time is killing you
We identify the constraint, fix handoffs, and rebuild flow from demand back through the process. Less waiting, less WIP thrash, faster changeovers, cleaner material movement. Throughput goes up without chaos.
Rework & Scrap Reduction
When defects are stealing capacity
We run root cause analysis the right way (DMAIC) and lock in controls—control plans, checks, and error-proofing (poka-yoke). Scrap and rework drop, first-pass yield rises, and the process stops “drifting.”
New Product Integration (NPI)
When you’re launching or moving production
We plan and execute integrations and transitions: equipment installs, product ramps, and line rework. Clear gates, risk control, training, and run-at-rate readiness—so production keeps running while you change.
Pick the problem that’s costing you the most. We’ll start there.
How we work
Define the problem
Make work visible. Set the baseline.
We start by making the work visible—where time is lost, where defects are born, and where flow breaks. You get a prioritized problem list, a baseline (cycle time, WIP, FPY), and a 30/60/90 plan with owners.
Stabilize the process
Lock in standard work and daily control.
We stabilize the line with standard work, visual management, and daily accountability. Downtime reasons get defined and categorized, then eliminated. The goal is a predictable process you can run the same way every shift—without firefighting.
Improve flow and quality
Remove constraints. Reduce defects.
We attack the constraint and rebuild flow from demand back through the process—less waiting, less WIP, faster changeovers, cleaner handoffs. In parallel, we run root cause the right way (DMAIC) and install controls: control plans, checks, and error-proofing (poka-yoke) so scrap and rework drop and FPY rises.
Sustain and scale
Make performance repeatable—and keep it that way.
We hand off a control system your team can own: KPI definitions, leader standard work, audit routines, training, and simple escalation rules. For New Product Integration (NPI) or Factory/Production Line Transition work, we add gates, risk control, and run-at-rate readiness—so change happens without breaking production.
Proof beats promises
Downtime stops being debated
Delivered categorized downtime reasons, a daily accountability rhythm, and a standard work refresh—so losses are visible, owned, and eliminated.
The constraint gets protected and fed
Delivered constraint analysis, handoff fixes, pull signals, and changeover discipline—so flow improves without chaos or excess WIP.
Defects get removed—and controlled
Delivered DMAIC root cause, control plans, checks, and poka-yoke (mistake-proofing)—so scrap/rework stops creeping back.
Who we are
Practical, floor-first operations improvement—built to survive real pace, real people, real constraints.
We install fixes your team can run every shift.
Boiler Agency helps manufacturers stabilize output, improve flow, and reduce defects—without breaking production to do it. The work starts on the floor: observe the process, baseline the reality, and identify the constraints and failure modes that are stealing capacity.
You get implemented improvements—standard work, visual management, constraint relief, quality controls, and training that sticks—backed by before/after evidence and a control system your team can own. For New Product Integration (NPI) and line transitions, we add gates, risk control, and run-at-rate readiness so change happens without chaos.
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