high mix manufacturing

Manufacturing and Operations Strategy Consultants

CalAmp, Inc.

  DEHART CONSULTING, INC.'s flow-based manufacturing methods enabled California Amplifier to significantly reduce floor space, manufacturing cycle-time, and overhead staffing requirements, reduce our material costs by nearly 20%, while over tripling California Amplifier's inventory turns to 10+...  

Fred Sturm, President and CEO California Amplifier, Inc.

DeHart Consulting (DCI) is unique among manufacturing management consulting firms in that we use a team-based approach in the vast majority of our assignments. We have found over the years that results are much better when the client's personnel are brought into the work early and when key client stakeholders are involved with our lean manufacturing consultants. While this approach requires an investment of time from the client, it increases overall commitment and a buy-in that paves the way for the implementation of the work.

This approach also provides a positive work environment, which is productive and essential to the overall effectiveness of any industrial engineering project and the success of our clients. This is especially the case in lean manufacturing consulting assignments where the result of the work requires considerable change management.

Whether your organization is a mature or start-up business, our senior extentive experience will assist your organization in a variety of practice areas.

Practice Areas

Manufacturing Facility Design
DeHart Consulting is an industrial engineering firm whose strength is in implementation of facility designs. Working with the client’s end users, architects, and facilities professionals, we will handle the project from concept to completion.
Engineering Lab Design
DCI's Engineering Lab Design Consultants extensive industrial engineering experience in the electronics, photonics, and semiconductor industry, we are uniquely positioned to understand these requirements and translate them into innovative, flexible, and enduring engineering lab designs.
Supply Chain Development
DCI provides consulting services in the area of supply chain strategy, advising clients in the areas of commodity management procurement processes, and procurement contract development.
Product Cost Reduction
In highly competitive markets, achieving product cost goals the product of setting the right goals and dedicating the organizational resources necessary to achieve them.
Software Development
DCI has developed simple and effective add-on software for common ERP systems that enable the use of demand-pull, just-in-time supply chain logistics policies.
Demand-pull Shop Floor
Vortex TM is a patented software developed for high-mix, non-repetitive manufacturers as an outgrowth of the DCI's Lean Manufacturing methodologies.

Why Dehart Consulting?


    DCI partners are Individuals with a minimum of 20 years of experience in business process re-engineering, strategic procurement, and operations management, who operate solely for the benefit of the client. Each partner has expertise in an area of operations management, lean manufacturing, and manufacturing cost reduction, which is critical to the specific needs of each operations management project.
    Partner skills include Strategic Procurement, Lean Factory & Warehouse Design, Product and Manufacturing Cost Reduction, and manufacturing software services.

    DCI's team-based consulting increases overall project commitment and buy-in which paves the way for full implementation of the work being designed. We have found over the years that when the client's personnel are brought into the project early and when key client stakeholders are involved in the assignment, the results are stunningly successful. While this approach requires an investment of time from the client, the investment greatly enhances the probability of a successful implementation.

    Our consulting team offers a vast array of expertise for your specific needs. Facility Design (Manufacturing and Technical Spaces), Manufacturing Process Development (Electronics, Photonics, and Microelectronics), Supply Chain Development, Operations Performance, Benchmarking, Operations Organizational Development, NPI Development Track Definition, Material Cost Reduction, Procurement Contracts, Acquisition Due Diligence, Production and Materials Planning Processes, Lean Manufacturing Processes Just-in-Time, Visual Production Scheduling are all in our wheel-house! Contact us today to learn more.

    DeHart Consulting focuses on the swift and cost-effective implementation of operations management change, not paper studies or open-ended recommendations. Results that make a difference to your bottom line.

    • Reducing job shop manufacturing lead times
    • Increasing On-time Delivery
    • Increasing business process speed
    • Reducing Engineering design time
    • Increasing factory productivity
    • Manufacturing cost reductions
    • Reducing material costs

    With extensive experience in:

    • Manufacturing Cost Reduction
    • Production Cycle-time Reduction
    • Lean Manufacturing
    • Outsourcing
    • Performance Benchmarking
    • Materials Acquisition Cost Reduction
    • Facility Design
    • Acquisition-related Due Diligence
    • Production Planning Systems

    Count on DCI to swiftly deliver cost-effective recommendations for your operations.


    Your start-up business will benefit from our experience in:

    • Supply Chain Strategy/Design
    • Outsource Partner Development
    • Operational Infrastructure Development
    • ERP Systems Design/Selection
    • New Product Introduction Process
    • Design For Manufacturing
    • Manufacturing Process Development
    • Interim Management

    Contact us today for more information.

Lockheed Martin SB Focal Plane

Manufacturing Facility Design | Goleta, CA

lockheed martin practise areas

lockheed martin 180

Manufacturing Fabrication & Assembly

Goleta, California

Project Type

Project Size
240,000 sf

Project Duration
Design – 6-months
Build – 9-months

LM-SBFP is a world-wide leader in the design and fabrication of defense and aerospace components and was tasked with doubling its production throughput within its existing manufacturing footprint. DCI was hired to redesign the factory layout within the context of lean manufacturing principles and to assure the overall capacity increase.

The high-mix production environment involved a broad range of processes and products. DCI analyzed the value chain and reworked the facility layout delivering a 3x reduction in production span and the needed 2x increase in capacity.

A novel technology for demand-pull production was proposed to minimize floorspace dedicated to work-in-process inventory. Design Engineering, Facilities, and Operations Management staff we part of the team that assured the designs met the needs of all involved.

The design won the approval of corporate management and was implemented over a 2-year period.


  • Lean Manufacturing
  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Information Technologies
  • ESD Facilitation

XILINX, Inc. AsiaPac Headquarters

Manufacturing Facility Design | San Jose, CA | Singapore

xilinx practise areas


xilinx practise areas 2xilinx practise areas

lockheed martin 180

Manufacturing, Engineering, & Distribution Center

Changi Business Park, Singapore

Project Type

Project Size
290,655 sf

Project Duration
18 months

Xilinx Inc is the leader in programmable logic devices with 50% of the world market share. In the brief to DCI, space efficiency and sustainability was a core design consideration.

The warehouse is designed with automation in mind with direct material handling conduits to the production floor. Smart features such as air flushing, light management system and intelligent environmental features provide a productive working environment.

Tasked to ensure the incorporation of worldwide demand projections to Xilinx’s headquarters, DCI proposed features that enabled a mere 1.1% increase in construction investment but reaps an expected $500,000 savings each year.  DCI was responsible for analyzing production rates and capacity to assure that the resulting design was capable of meeting the needs of the 5-year forecast.

The project was awarded Platinum Green Award by Building & Construction Authority of Singapore, the first ever for a privately developed industrial facility.


  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Warehouse Automation
  • ESD Facilitation
  • Security