01
Operations Diagnostics
A hard look at where money leaks — throughput, quality, labor, flow. Findings in weeks, not quarters.
FIND THE LEAKIRONLINE — OPERATIONAL TURNAROUND
FIX WHAT'SBROKEN.THEN MAKEIT RUN.
We turn around operations that are losing money — throughput, margin, and the systems underneath. Hands on the floor, measured in dollars and days.
SCROLL — WALK THE LINE
01LV.01 / CAPABILITIES
THE LINE — SIX MEMBERSSix ways we take weight off a struggling operation. We scope to the diagnosis — no padded engagement, no services you didn't need.
02
Throughput & Margin
Unclog the constraint, raise output, pull cost back out of the line. Recovery you can read on the P&L.
LIFT OUTPUT03
Turnaround Management
Hands-on command of a plant or unit in trouble. Stabilize cash, steady the floor, reset the plan.
STOP THE BLEED04
Supply Chain & Procurement
Tighten sourcing, inventory, and logistics. Fewer stockouts, less tied-up cash, cleaner landed cost.
FREE THE CASH05
Performance Systems
The daily management, metrics, and standards that keep the gains after we're gone. Built to run without us.
HOLD THE GAIN06
Interim Leadership
A seasoned operator in the COO or plant-manager chair while you stabilize or hire. Grip from week one.
TAKE THE SEAT02LV.02 / WHERE IT BLEEDS
CASH — LEAVING THE BUILDINGMISSED SHIPMENTS.MARGIN GONE.A FLOOR THATSTALLS.
Every idle machine, every rerun, every expedited freight bill is cash leaving the building. It rarely lands as one big number — it bleeds out a hundred small ones, until the quarter's already gone.
03LV.03 / THE MANDATE
ACCOUNTABILITY — ONE SEATOne operator, accountable for the whole line.
No deck handed to your team to figure out. We take the constraint, run the fix on the floor with your people, and stay on the number until it moves.
04LV.04 / WHAT WE MOVE
MEASURED — DOLLARS & DAYS0%
Average throughput lift in the first 90 days
$0.0M
Operating cost pulled out of client lines to date
0+
Plant, warehouse, and supply-chain turnarounds led
0d
Median days to first measurable recovery
Run by operators who've carried the number themselves — not analysts renting you a deck.
05LV.05 / THE METHOD
PHASE 01 → 04PHASE 01
DIAGNOSE
Two weeks on the floor and in the numbers. We find the constraint and size the prize.
PHASE 02
STABILIZE
Stop the bleed first — cash, quality, and the fires that keep the floor reactive.
PHASE 03
REBUILD
Fix the constraint, lift throughput, and rebuild the daily management that holds it.
PHASE 04
HAND OFF
Your team runs it and owns the metrics. We work ourselves out of a job.
06LV.06 / FIELD RECORD
90 DAYS — VERIFIEDCASE 01 — MIDWEST STAMPING PLANT
Three weeks from closing. Shipping on time by quarter's end.
A 400-person stamping plant was losing $300K a month to scrap, downtime, and expedited freight. Ninety days on the floor and it was cash-positive and hitting its dates.
“They didn't send consultants. They sent operators who knew our machines better than we did.”VP Operations — Midwest stamping plant
07LV.07 / MANAGING DIRECTOR
SIGNED — D. KANEDale Kane
Managing Director · Turnaround operator
Cleveland, Ohio · On-site across North America.
I've run plants that were three weeks from closing and shipping again by quarter's end. Twenty-two years on factory floors, in distribution centers, and in the seat when the numbers had to move.
Before Ironline I was a plant manager, then the turnaround COO for a mid-market manufacturer everyone had written off. We didn't write it off.
You get an operator who's carried the number — not an account manager learning on your floor.
“If it doesn't show up on the P&L or the shipping dock, it isn't a result. We bill for numbers you can measure.”
RES / FREE TOOL
FREE TOOL — THE BLEED RATE CALCULATOR
See what downtime is quietly costing your line.
Unplanned downtime bleeds out in small numbers — idle labor, scrap, expedited freight. Run your line's numbers and the report is in your inbox in sixty seconds.
- 01Your line's annual bleed rate — downtime cost in dollars, not percentages.
- 02Where it's leaking: idle labor, scrap and rework, expedited freight.
- 03Cost per downtime hour, benchmarked against your sector.
- 04The three fixes that recover the most, fastest.
08LV.08 / SPECIFICATIONS
GENERAL NOTESFirst measurable recovery is usually inside 90 days. The diagnostic gives you a sized target and a timeline before you commit to the full engagement.
No. We run the fix on the floor with your team. The report is a byproduct — the moved number is the deliverable.
No. Manufacturing, distribution, warehousing, and supply-chain operators — anywhere throughput and margin live in physical operations.
Mid-market, roughly $20M–$500M in revenue, single- or multi-site. Big enough to matter, small enough to move fast.
A fixed diagnostic fee, then engagement fees tied to the recovery. If the number doesn't move, most of our upside doesn't either.
LV.09 / THE NEXT MOVE
START WITHTHEDIAGNOSTIC.
Two weeks on your floor and in your numbers. You leave with the constraint named, the recovery sized, and a plan you can run — with us or without us.
Fixed fee · Two weeks · A sized target, not a sales pitch.