Aerospace throughput, capacity & rate readiness consulting · Greater Seattle
The capacity you need is already on your floor
Fixed-fee plant performance and capacity engagements for aerospace and space manufacturers doing discrete fabrication and assembly in the Greater Seattle area. I recover performance from existing operations, prepare production systems for higher rates, and validate major capacity decisions before money is committed, tested in simulation where the decision warrants it.
Start the conversationThroughput recovery · Operating cost reduction · Rate readiness and capacity planning · Production system and conceptual facility planning · Discrete-event simulation
Relevant operating results
Results from production systems I worked in and consulted on.
Performance recovery is measured in output and cost. Typical opportunities include overtime, scrap, rework, excess WIP, labor lost to imbalance, and capital purchases that can be deferred or avoided.
Problems I help solve
In the existing operation
- Missed delivery commitments.
- Recurring overtime.
- Excess WIP and long lead times.
- Labor imbalance across stations and shifts.
- Scheduling instability.
- Scrap and rework driving cost.
- High manufacturing operating cost.
- Output below what the people and equipment should deliver.
In growth and change
- A rate increase or new-program ramp.
- NPI and prototype-to-rate transitions.
- Production transfers and new production areas.
- Facility expansion and space requirements.
- Staffing, shift, and equipment quantity decisions.
- Layout and material flow.
- Phased labor and capital plans, validated before commitment.
The gap usually hides in handoffs, scheduling, and flow, not in the equipment. Recovering existing capacity first reveals what genuinely needs to be added.
Recover what is already there. Know exactly what to add when it is not enough.
Services
Three engagement paths, each fixed fee, time-boxed, and tied to a quantified operating decision.
Plant Performance Assessment
Fixed fee. Two weeks.
For an existing operation missing delivery, consuming overtime, or carrying high WIP and cost. Constraint and flow diagnosis, labor balance, and release logic, delivered as prioritized recovery actions in a sequenced plan. Existing-capacity recovery comes first, and any remaining investment is justified against the gap that is left.
Rate Readiness and Capacity Plan
Fixed fee. Time-boxed.
For a rate increase, NPI, production transfer, expansion, or new production area. The work defines demand and mix scenarios, process breakpoints, labor and equipment requirements, material flow, WIP strategy, floor space, and conceptual layout alternatives. The result is a phased hiring, equipment, and capital plan.
Simulation and Decision Study
Fixed fee. Time-boxed.
For decisions where averages and spreadsheets cannot capture variability, queues, shared resources, or constraint migration. Rate ramps, equipment and layout choices, staffing structures, and release sequencing, tested before money is committed.
Multi-area and multi-site programs scale any of these paths across lines or sites. Implementation support is scoped separately once a plan is in hand. An assessment carried through simulation is shown end to end in the case study.
Representative case study
One engagement, shown end to end. Floor analysis finds the constraint, simulation shows where it migrates next, and the area recovers hidden capacity before additional equipment or headcount is considered. The full study, Recovering hidden capacity, preparing for rate increases, follows four sequenced moves through the recovery.
Who runs the work
Every engagement is led and delivered directly by Daniil Tchistiakov. The person walking the floor also builds the analysis, develops the model, and presents the recommendation. Daniil previously optimized production and built product to rate inside Boeing Fabrication, then worked as a management consultant across diverse manufacturing plants. Each engagement is fixed fee, time-boxed, and tied to a quantified operating decision.
Is an operation underperforming, or is a rate or capacity decision approaching?
Send a few lines on what is happening, the outcome you need, and the timing in front of you. I will tell you whether a focused engagement makes sense.
Start the conversation