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Turnaround and scaling for fabrication businesses

Shaun Patrick Stewart leads operational turnarounds for fabrication and manufacturing companies, restructuring the shop, office, sales, and installation so a business produces more, remakes less, and makes money. Between 2011 and 2016 he did this for two granite, quartz, and solid-surface fabricators, working in Tampa, Orlando, and Sarasota, doubling to tripling weekly output at both.

What changed at the two companies

  • Company 1: weekly production went from about 1,200 to about 2,500 square feet.
  • Company 2: weekly production went from about 2,500 to about 5,000 square feet.
  • Both set company-record volumes that still stand.
  • Daily reworks dropped about 70 percent, even after volume doubled.
  • One company came all the way back from bankruptcy to sustained profitability.
  • The owners got to the point where they no longer needed to be on site every day.

How the turnaround works

Every remake is a lead. Each rework triggers a root-cause look and, usually, a permanent new procedure. That’s how rework falls while volume rises.

Fix the flow before adding capacity. Most shops don’t need another machine first. They need material ordered against a nested plan, templates that are right the first time, and a schedule built from real machine capacity.

One source of truth. Shop, office, install, and service all work from the same job record, so nobody re-enters data and nothing falls through.

Lead from the floor. I program the machines, walk the installs, and manage the accounts myself while the new system settles, including large commercial and high-volume hotel work with volatile demands.

Is this the right fit?

This is for owners whose shop is busy but not profitable enough, whose remake rate has become “normal,” or who can’t step away without things slipping.

FAQ

Do you work with shops outside stone and countertops? The same principles apply to most job-shop manufacturing with CNC equipment, templating, and installation.

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