Precision Metal Fabrication — Throughput & Profit Recovery
Re-engineered production flow, introduced kanban staging and QC checkpoints to transform throughput and margins.
Case Study Library — Business Optimization Labs
Lab-style diagnostics, treatment plans, and measurable outcomes for manufacturing, real estate, and service businesses. Each report includes BOL Health Audit scores, root-cause analysis, and CEO testimony.
Real Estate
90 days
Property Management — Ticket Time & Owner Trust
Implemented a stage-based maintenance pipeline and automated owner reporting to accelerate response times and restore investor confidence.
-72%
Ticket time
+11%
Profit per door
-28%
Door churn
Service Business
60 days
Premium Home Services — Route Optimization & Scale
Route optimization, morning staging, and SOPs that increased daily capacity and reduced owner reliance.
+22%
Daily capacity
+17%
Revenue/tech
-27 hrs
Owner hours
Manufacturing • 120 days
Precision Metal Fabrication — Throughput & Profit Recovery
Primary goals: Fix operations, increase profit margin, prepare for scale
1. Presenting Symptoms
The company had high inbound demand but unpredictable production. Jobs stacked, emergencies disrupted schedule, and profit margins were compressed despite sales volume.
“Always busy, never profitable.” — Owner
2. Diagnostic Findings — BOL Health Audit Scores
| Category | Score | Observation |
|---|---|---|
| Production Flow | 44 | Jobs queued and mis-sequenced; choke at welding & finishing |
| Scheduling | 41 | Owner-based scheduling led to emotional prioritization |
| Quality Control | 57 | Failures concentrated late in process |
| Inventory & Materials | 39 | Material waste ~13% |
| Leadership & Structure | 52 | Over-dependence on senior techs |
3. Root Cause Analysis
- No pre-staging; average job waited 2.2 days before fabrication started
- “Emergency” jobs comprised 23% of schedule, breaking flow
- Material tracking was absent — $8k–$12k monthly leakage
- Owner was decision bottleneck (~71% of decisions)
4. Optimization Treatment Plan
- Kanban-style production staging and capacity planning
- Weekly production planning meeting with capacity commitments
- 3-step QC (pre-fab ? mid-fab ? pre-install)
- Material tracking + basic inventory controls
- Training for a production coordinator and 22 SOPs documented
5. Results (45–120 days)
+33%
Throughput
+17.4%
Profit margin
-18 hrs
Owner weekly hours
$146k
Annual rework savings
CEO Testimonial
“We used to operate on stress and guesswork. In 120 days, BOL turned our chaos into a predictable system. Our profit margin jumped more in 3 months than in the previous 3 years. We’re finally scalable.” — Daniel R., CEO
6. Suggested Visuals for this case
- Before/After Gantt-style production chart (throughput by week)
- Bar chart: material waste % before vs after
- Owner hours timeline
Real Estate • 90 days
Property Management — Ticket Time & Owner Trust
Primary goals: Fix operations, reduce churn, increase profit per door
1. Presenting Symptoms
Rapid growth with friction: slow maintenance response, inconsistent investor reports, and long onboarding timelines created churn and owner dissatisfaction.
“We were drowning in little fires — and losing doors because of it.” — COO
2. Diagnostic Findings — BOL Health Audit Scores
| Category | Score | Observation |
|---|---|---|
| Maintenance Workflow | 48 | Average ticket open time 4.3 days |
| Communications | 52 | Owner reports built manually |
| Onboarding | 46 | 15–20 day onboarding for new doors |
| Team Role Clarity | 55 | Overlapping responsibilities |
| Financial Controls | 58 | No per-door cost tracking |
3. Root Cause Analysis
- Tickets touched multiple hands — too many handoffs
- Manual reporting created inconsistency and delays
- Onboarding lacked standardized intake and checklists
- Data transparency absent — owners lost confidence
4. Optimization Treatment Plan
- 5-stage maintenance pipeline with SLA timers
- Template-based automated owner reporting (80% automated)
- 3-day standardized onboarding intake
- Role clarity matrix + weekly Portfolio Health Review
5. Results (30–90 days)
1.2d
Avg ticket time
+11%
Profit per door
-28%
Door churn
CEO Testimonial
“Our business finally feels like a real company instead of a tire fire. BOL rebuilt our workflows and communication systems from the inside out. Owners trust us again — and we’re scaling confidently.” — Melissa T., Managing Broker & Founder
Service Business • 60 days
Premium Home Services — Route Optimization & Scale
Primary goals: Fix operations, increase revenue, scale without chaos
1. Presenting Symptoms
High demand but low predictability: long drives, missed windows, and owner burnout prevented reliable scaling.
“I felt like the bottleneck in my own business.” — Owner
2. Diagnostic Findings — BOL Health Audit Scores
| Category | Score | Finding |
|---|---|---|
| Dispatch & Routing | 49 | Technicians driving 40% extra per day |
| Sales-to-Fulfillment | 53 | Work orders not prepped before arrival |
| Customer Experience | 62 | Delays in follow-up & missed windows |
| Financial Leakage | 42 | No job profitability tracking |
| Leadership Ops | 51 | Owner doing scheduling & approvals |
3. Root Cause Analysis
- Route inefficiencies produced wasted drive time (45–75 min/day)
- No morning staging resulted in preparation delays
- Owner approval requirements slowed dispatch
- No SOPs ? quality inconsistency and missed revenue
4. Optimization Treatment Plan
- Route optimization & technician zoning
- Morning staging process to save collective hours
- Skill matrix + skill-based dispatch
- Upsell scripts and SOP library (14 SOPs)
5. Results (30–60 days)
+22%
Daily capacity
+17%
Revenue / tech
-27
Owner hrs / week
CEO Testimonial
“This felt like taking my business through a medical scan. We finally saw the real problems, fixed them, and grew fast — without adding staff. BOL gave us the roadmap we didn’t know we were missing.” — Chris J., Owner