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LAKEHURST CONSULTING
dan@lakehurstconsulting.com | 📞314-270-2476
For Manufacturing Leaders Who Are Done Firefighting
Stop Losing $500K–$2M Annually to Operational Chaos
There's a reason your problems keep recurring: You're treating symptoms, not building systems.
I've spent 30+ years eliminating waste in chemical plants, mining operations, and manufacturing facilities—not from a textbook, but from the factory floor up.
I don't fix your problems for you. I build the problem-solving capability within your team so they fix problems permanently.
Limited availability—I only work with 6 clients at a time
- Certified Management Consultant® (CMC®)
- Lean Six Sigma Black Belt
- 30+ Years Manufacturing Operations Experience
Dan Pinkham - Founder Lakehurst Consulting
You're Not Alone. Every Manufacturing Leader I Work With Says the Same Thing:
Here's the truth most consultants won't tell you: Your problem isn't the equipment, the people, or the suppliers. Your problem is you don't have a structured system for solving problems—so you're stuck in an endless loop of reactive firefighting.
The One-on-One Operational Excellence System™
Most consultants fix problems FOR you, then leave. Their solutions die the moment they walk out. I do the opposite: I build problem-solving capability WITHIN your team, so improvements compound long after I'm gone.
1. Practitioner-Led, Not Theory-Driven
30+ years running chemical plants, fiberglass manufacturing, and mining operations. I've been in your shoes—I know what actually works on a factory floor at 2 AM when things go sideways.
2. Embedded Coaching, Not Classroom Training
We solve real problems together using your data, your team, your operations. No generic playbooks. No off-site workshops that everyone forgets by Monday.
3. Sustainable Systems, Not Temporary Fixes
By the time we're done, your team has the methodology, tools, and confidence to solve problems permanently—and prevent new ones.
Why Manufacturing Leaders Trust Dan Pinkham
30+ Years Experience
- Chemical Production
- Fiberglass Manufacturing
- Mining (3 continents)
- Food Processing Equipment
- Medical Device Manufacturing
Led operations, engineering, asset care, and operational excellence at both site and corporate levels.
Credentials
Certified Management Consultant® (CMC®)
Rigorous examination by Institute of Management Consultants USA. Fewer than 1% of consultants earn this.
Certified Lean Six Sigma Black Belt
Plus Master Black Belt training
BS Chemical Engineering
University of Maine
MBA
Marshall University
Recognition
- Featured Expert, Close Up Radio
- 2022 Small Business Superstar – Greater KC Chamber of Commerce
- Speaker, 2012 International Maintenance Conference
- Panelist, KC SmartPort Industry Briefing
- Two US Patents for energy reduction innovation
The Results Speak for Themselves
$165M
Total Savings Generated
Multinational mining company, 9-year program
3–8%
Average Cost Reduction
Typical client results in first 12 months
1,200+
Employees Trained
Who now drive improvements independently
27.5hrs
From 1 Week to 27.5 Hours
Mining downtime reduction (+10% capacity)
Mining Downtime Reduction
The Challenge:
UK mining company facing severe downtime (1 week per pullback). Winter inventory crisis creating political pressure.
The Solution:
Facilitated kaizen event, mapped all pullback steps, identified waste and resource conflicts, built future-state plan.
The Result:
Reduced downtime from 1 week to 27.5 hours average—unlocking 10% additional annual capacity.
Multi-Site Mining Program
The Challenge:
$1.4B mining company (14 sites, 3,100 employees) needed to offset inflation through productivity gains.
The Solution:
Established 8-year Operational Excellence process: training, execution approach, project tracking, assessment.
The Result:
Met annual 3-5% cost reduction goals from 2008-2018. Total savings: $165M. Trained 50%+ of workforce.
Wire Manufacturing Lead Time
The Challenge:
World-class medical device wire manufacturer with 130+ steps and 35 teams—custom product lead times too long.
The Solution:
Cross-functional kaizen event to map all steps, identify streamlining opportunities, develop detailed procedures.
The Result:
Client used output to streamline product development process, significantly reducing lead times.
How We Work Together
This isn't a "spray and pray" training program. It's a structured, hands-on engagement designed to solve real problems while building your team's capability.
1
Discovery & Diagnosis
We start with a deep-dive diagnostic to identify your biggest profit leaks and operational bottlenecks. No generic assessments—we use your data, your processes, your team's input.
2
Problem Definition & Roadmap
Together, we define the true root problems (not symptoms) and build a prioritized roadmap. Your team is involved from day one—this is their plan, not mine.
3
Hands-On Implementation
We work side-by-side with your team to implement solutions using proven Lean Six Sigma tools. They learn by doing, not by sitting in a classroom.
4
Measurement & Refinement
We track results quantitatively—no fluffy metrics. If something isn't working, we adjust. If it is, we document it so it's repeatable.
5
Capability Transfer
By the end, your team owns the methodology. They can solve future problems independently. That's when you know it worked.
IMPORTANT: I only work with 6 clients at a time.
Why? Because this approach requires personal attention. I'm not running a consulting factory—I'm building long-term capability in your operation.
That means availability is limited. If you're serious about transforming your operations (not just patching problems), let's talk.
Three Ways to Work With Me
Every manufacturing operation is different. I offer flexible engagement models to match your situation, urgency, and budget.
12-Week Guided Profit Acceleration
Best for: Companies ready to build internal capability
What You Get:
- Weekly 90-minute coaching sessions (12 weeks)
- Async Slack/email support
- Comprehensive training modules
- Guided problem-solving on real issues
Investment: Starting at $47,000
Perfect if you have a capable team that needs structured methodology and expert guidance—but you want them doing the work (and owning the results).
90-Day Profit Recovery Sprint
Best for: Urgent situations requiring intensive intervention
What You Get:
- On-site presence 2–3 days/week
- Direct work with your team on critical problems
- Rapid diagnostic and implementation
- Comprehensive training and documentation
Investment: Starting at $97,000
This is the "all-in" approach. When you need fast results and hands-on expertise embedded in your operation, this is how we deliver.
VIP Consulting
Best for: CEOs and executives needing strategic guidance
What You Get:
- Direct access to Dan Pinkham
- Custom engagement designed for your needs
- Board/investor presentation support
- Due diligence for M&A/PE transactions
Investment: Custom (typically $150K+)
For leaders who need senior-level operational expertise without the overhead of a full-time executive.
Not sure which is right for you? That's what the strategy session is for. We'll assess your situation, identify your biggest opportunities, and recommend the best path forward—even if that means NOT working together.
What Makes This Different from Every Other Consultant?
Q: "We tried Lean Six Sigma before. It didn't work. Why would this be different?"
A: Most Lean implementations fail for one reason: they're all training, no execution. You sent someone to a certification class. They came back excited. They tried to apply it. Nobody else understood it. It faded away. I don't do classroom training. We solve real problems in your operation using Lean tools. Your team learns by doing—and by the time we're done, they OWN the methodology.
Q: "We're too busy to pull people off the line for this."
A: You're too busy because you're stuck in firefighting mode. The reason you're too busy is EXACTLY why you need this. We break the cycle. Once your team has a structured problem-solving system, they work smarter—not harder. Plus, we work with your schedule. We don't shut down operations to "do Lean." We improve operations while they're running.
Q: "Can't we just hire someone full-time to do this?"
A: You could. But a full-time hire costs $80K-$120K + benefits. They take 6-12 months to ramp up. If they leave, the knowledge walks out the door. With me, you get 30 years of manufacturing expertise, proven methodology, and capability transfer—meaning when we're done, your team can continue without me. Faster results. Lower risk. Sustainable capability.
Q: "How do I know this will actually deliver ROI?"
A: If your operation is doing $50M in revenue, a 3% cost reduction (my typical minimum) is $1.5M. If we achieve that in the first year (which we typically do), you've generated 10-30X ROI depending on the engagement model. The real question isn't "Can I afford this?"—it's "Can I afford to keep bleeding money to inefficiency?"
Q: "What if our operation is too unique/complex for standard approaches?"
A: Good. I don't do "standard approaches." I've worked in chemical plants, mining operations, fiberglass manufacturing, food processing equipment—every one thought they were unique. And they were right. That's why I don't bring a generic playbook. We use proven tools adapted to YOUR specific operation, YOUR constraints, YOUR opportunities. The methodology is universal. The application is custom.
Q: "Why do you only work with 6 clients at a time?"
A: Because I'm not trying to build a consulting empire. If I took on 20 clients, I'd need a team. I'd become a manager, not a practitioner. You'd get "my people," not me. I built this firm to do hands-on work with manufacturing leaders who are serious about transformation—not to scale a consulting factory. Quality over quantity. Always.
To get out of the pit we require an outside view. No chance from the inside. A system cannot understand itself. Understanding comes from outside.
— Dr. W. Edwards Deming, Father of the Quality Movement
You can't read the label when you're inside the jar. That's not a failure on your part—it's just reality. You're too close to your own operation to see the systemic issues. That's where I come in.
Ready to Stop Firefighting
and Start Leading?
I only work with 6 clients at a time—and I'm selective about who I work with.
This isn't for every manufacturing leader. It's for leaders who:
- Are tired of temporary fixes and want permanent solutions
- Understand that transformation requires investment (time, money, focus)
- Are willing to empower their team (not just dictate solutions)
- Want to build capability, not dependency on a consultant
If that's you, let's talk.
The application takes 5 minutes. If you're a fit,
we'll schedule a 45-minute strategy call where I'll:
- Identify your top 3 profit leaks
- Show you the roadmap to fix them
- Recommend the best engagement model for your situation
No pressure. No obligation. Just clarity on what's possible.
⚠ Current availability: 2 open spots for this quarter
Contact
Lakehurst Consulting, LLC
Dan Pinkham, Principal Consultant
Email: dan@lakehurstconsulting.com
Phone: 314-270-2476
Hours: 8:00 AM – 5:00 PM CST
Credentials
Certified Management Consultant® (CMC®)
Member, Institute of Management Consultants USA
Certified Lean Six Sigma Black Belt
Veteran, Chemical/Process Manufacturing
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