Systems That Stick.
Floors That Run.
Operational process consulting for corrugated and folding carton packaging manufacturers.
We help corrugated and folding carton packaging manufacturers dealing with inconsistent workflows — to standardize processes, document acquired knowledge, and hit production KPIs consistently.
Losing Money
Every Shift.
Setup Times Miss Targets
Every minute over your setup target is lost throughput. When operators run the same machine differently every shift, you can't predict your output — and you can't hit your KPIs.
No Documented Workflows
When your best operator leaves, their knowledge walks out with them. Without documented SOPs, every new hire starts from zero and every supervisor enforces a different standard.
Inconsistent Training
Tribal knowledge is not a training program. When there's no standard to train against, output varies by person, by shift, and by day — and quality and throughput suffer for it.
The Employee-Management Gap
Supervisors push production. Workers push back. Without a clear accountability framework, morale erodes, good employees disengage, and your floor runs on frustration instead of process.
Experience.
Consultant-Level
Results.
Workflow First Consulting was built by someone who has actually run the equipment, timed the setups, and fixed the problem from the inside out — not from a conference room.
With hands-on experience efficiently setting up and operating packaging equipment across multiple departments — including flat and rotary die cutting, flexographic and offset printing, foil stamping, and embossing — and 15 years improving production processes across corrugated and folding carton packaging manufacturing, we bring a perspective most consultants simply don't have: we've done the job.
We work with mid-size packaging manufacturers — corrugated and folding carton — who are serious about building a floor that runs consistently with or without us in the building. Every engagement ends with something your team owns: a documented system, a trained crew, and a standard that holds.
We are not a large firm. We do not send a junior analyst to your floor. When you hire Workflow First Consulting, you get one experienced operator-turned-consultant who understands your equipment, your people, and your problem.
Sub-30 Minute Setup Target — Achieved
Proven ability to reduce setup times from 55+ minutes to a consistent sub-30 minutes through independent workflow analysis and optimization.Detailed SOP — Written and Deployed
Authored a complete machine operations and training manual with photos and diagrams, still in active use on the production floor.Dual Perspective — Floor and Management
Experience on both sides of the production floor: as a supervisor managing throughput targets and as an hourly operator understanding what workers actually need to succeed.To Work
Together.
- On-site workflow walkthrough — observe setup start to finish
- Timed task analysis — find exactly where time is lost
- Root cause identification — people, process, or documentation gap
- Written findings report — prioritized fix list
- One remote follow-up call to walk through findings
- Full workflow audit (month one deliverable)
- Custom machine-specific SOP with photos and diagrams
- On-site operator training session
- Supervisor coaching — remote, monthly cadence
- Monthly on-site check-in visit
- Weekly 30-min remote check-in call
- KPI tracking sheet — daily setup time log
- One SOP revision after 30 days of real-world use
- ★ Purchased a Tier 1 Audit within the last 30 days? The $2,500 is credited toward your first month.
- Everything in The Process across multiple machines or shifts
- Full training manual with onboarding checklist
- New hire onboarding system — train from the manual alone
- Supervisor development — accountability and floor management
- Morale and retention framework
- Ongoing SOP maintenance as processes change
- On-call operational support between sessions
- End-of-engagement report with before/after KPIs
Value Stream Mapping
5S Implementation
Standalone SOP
Kaizen Event
One Standard.
Assess
We come to your floor, observe your setup process start to finish, time every task, and identify exactly where the inconsistency lives — people, process, or documentation.
Build
We design the optimized workflow, write the SOP, and build the training materials your team needs to execute it consistently — every shift, every operator, every time.
Train
We train your operators on the new standard on-site, and coach your supervisors remotely on how to hold the line and maintain accountability without burning out the crew.
Sustain
We monitor KPIs, update the SOP as conditions change, and stay available for questions. The goal is a system that runs without us — and that's exactly what we build toward.
Say.
We are currently completing our first client engagements. Verified testimonials will appear here — from real plant managers, with real results, on real floors.
About Your
Production Floor.
Stop Losing Throughput.
Every shift your floor runs without a standard process is money left on the table. Let’s identify your biggest bottleneck, build a process that sticks, and train your crew to maintain it.
Download our free Productivity Planning Spreadsheet — a simple Excel template built to help you track Employee Training and KPIs with a Process Audit Checklist that is pre-built and ready to work for you. It's free, takes seconds to grab, and lands straight in your inbox.