Find the Capacity Hidden on Your Shop Floor.

We eliminate shop-floor bottlenecks, reduce scrap, and unlock hidden capacity—building high-performing visual environments for plants with or without an ERP.

Real-World Operational Leadership for the Shop Floor You Have Today

FOR DATA-BARREN & NON-ERP PLANTS

You run on paper travelers, whiteboards, and experienced operators. When output drops, you lack the data to prove why.

How We Help: We deploy hands-on 48-hour floor tallies, time studies, and physical visual huddle boards to build your first operational baseline without buying expensive software.

FOR ERP-EQUIPPED PLANTS

You spent heavily on software, but your shop floor still battles unrecorded rework, late setups, and missing tools.

How We Help: We translate your digital data into physical, floor-level visual controls and daily supervisor habits that close the gap between your system targets and actual shop output.

HOW WE HELP: OUR THREE ENGAGEMENT TIERS

1. The 2-Day Operational Diagnostic

Rapid Shop-Floor Baseline & Financial Bleed Analysis

A rapid, floor-level audit designed to mathematically isolate your top cost leaks, identify constraint work centers, and build your plant’s first true operational baseline—with or without an ERP.

What We Do On-Site:

  • Hands-On Gemba Walk & Stopwatch Time Studies

  • 48-Hour Physical Floor Tallies

  • Bottleneck & Takt Pace Calculation

  • Pilot Visual Prototype Setup

  • ERP vs. Floor Reality Audit (If Applicable)

Executive Deliverable:

A 1-Page Executive Scorecard Report detailing your baseline metrics, extrapolating 48-hour tallies into annualized profit bleed figures, and providing a prioritized roadmap for rapid margin recovery.

2. Fractional Director of Operations

Embedded Weekly Floor Leadership & Visual Management

Ongoing, hands-on operational leadership designed to build permanent visual systems, eliminate daily floor friction, and coach your shift supervisors into a proactive, high-performing team.

What We Build & Coach:

  • Permanent Low-Tech Visual Controls

  • Daily Shift Huddle Cadence

  • 3-Day SMED Quick-Changeover Sprints

  • Two-Bin Visual Kanban Systems

  • Floor-to-System Alignment

Engagement Model:

Dedicated weekly on-site presence, active floor coaching, and direct partnership with executive ownership.

3. Project Transformation Sprints

Intensive Line Re-Engineering & Bottleneck Removal

High-intensity, multi-week execution sprints targeted at resolving complex bottlenecks, physically reconfiguring production lines, and locking in structural throughput improvements.

What We Deliver:

  • Targeted Line Re-Engineering & Balancing

  • Cellular Kaizen & Setup Events

  • Visual Standard Work Installation

  • Buffer & WIP Management

  • Leader Process Audits (LPA)

Engagement Model:

Turnkey project execution with structured milestone deliverables and full operational handoff.

WHY FRONT RANGE OPERATIONAL SOLUTIONS?

Front Range Operational Solutions LLC was founded by Jesse Farley to provide practical, hands-on operational leadership to Front Range manufacturers across Colorado. Built on Lean principles, rigorous time-study methodologies, and a deep respect for floor-level craftsmanship, we partner directly with shop owners, plant managers, and shift leads to build high-performing, accountable production environments.

  • Shop-Floor First Mentality: We don't advise from behind a computer in an office. We put on safety glasses, walk your lines, and work shoulder-to-shoulder with your supervisors.

  • Measurable ROI: Every engagement is structured around hard financial metrics—reducing scrap, eliminating unplanned overtime, and raising On-Time In-Full (OTIF) delivery.

  • 100% Local Presence: Based in Colorado Springs, providing rapid, responsive on-site support across El Paso County and the Front Range.

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READY TO UNLOCK CAPACITY ON YOUR SHOP FLOOR?

You don't need months of historical data or complex software to fix shop-floor bottlenecks. Let's discuss your facility's current shipping targets, primary operational headaches, and how a 2-Day Tier 1 Diagnostic can establish your first operational baseline.

Let’s Optimize Your Operations

Contact us for a 20-minute operational discovery call.

Your operational data and blueprints remain 100% confidential.