Verified Results

Real Work.
Real Numbers.

Every result on this page came from an embedded Nextep engagement — not a survey, not an estimate, not a projection. Verified savings from actual client records. Client identities withheld on request.

$35M+
Total Combined Client Savings Delivered
10+
Industries
12x+
Avg. ROI
30+
Engagements

Engagements

Select Case Studies.

Pulp and paper mill
Pulp & Paper Program Lead

Multi-Workstream Operations Excellence Program

Embedded program lead across five simultaneous improvement workstreams — Kaizen, SMED, DMAIC, reliability, and winder optimization — at a large North American pulp and paper manufacturer.

$1.1M
Verified Savings — Month 5
72%+
Downtime Reduction
$2.64M+
Annual Trajectory
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Packaging and print
Packaging & Print Operations Assessment

Operations Excellence Assessment — Packaging Manufacturer

Structured operations diagnostic quantifying speed losses, capacity gaps, and utilization failures invisible to management — delivering a complete waste picture and prioritized improvement roadmap.

$247K
Q1 Waste Identified
$988K+
Annual Opportunity
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Aerospace manufacturing
Aerospace & Defense 3P Implementation

3P Production Redesign — Aerospace Manufacturer

Full 3P methodology deployment — Seven Flows analysis, 7-Ways workshops, moonshine prototyping — redesigning the production system from first principles while simultaneously standing up a brand-new production line.

65%+
Cycle Time Reduction
1
New Line Stood Up
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Production data systems
Industrial Manufacturing Digital Systems

Production Data Management System — Industrial Manufacturer

Full Tier 2 Production Data Management System designed and deployed from scratch — PLC integration, real-time custom dashboards, ERP/MES configuration, predictive analytics, and mobile access.

3–4
Weeks to Go-Live
Real-Time
Production Visibility
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Industries Served

We Work Where
Manufacturing Is Hard.

Nextep has delivered embedded programs across 10+ industries — from regulated aerospace to high-volume consumer packaging. The methodology is consistent. The results are verified.

Pulp & Paper
Multi-workstream lean programs, SMED, reliability, OEE improvement at large-scale mill operations.
Packaging & Print
OEE assessments, waste quantification, changeover reduction, and throughput programs in high-SKU environments.
Aerospace & Defense
3P new line design, cycle time reduction, standard work development in ITAR-controlled production environments.
Food & Dairy
Throughput, sanitation-aware changeover, and OEE programs in high-cadence, regulated processing environments.
Steel & Metals
Reliability, yield recovery, and flow improvement across heavy, high-temperature continuous operations.
Energy
Asset reliability, planned-maintenance conversion, and downtime reduction in continuous-process facilities.
Paint & Coatings
Batch changeover reduction, waste elimination, and quality-loss DMAIC in formulation-driven production.
Financial Services
Process mapping, standard work, and operational excellence applied to high-volume back-office workflows.
Healthcare
Flow design, waste reduction, and standard work in patient-throughput and service-delivery operations.
Industrial Manufacturing
Custom production data systems, OEE improvement, and embedded lean leadership across mixed-model lines.

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