Plants run better when the system does.
North Plant Consulting brings Toyota Production System discipline to manufacturing plants — production control, standardized work, daily management, and the visual systems that make on-time delivery hold.
Request a Consultation Explore ServicesSeven capabilities that make a plant deliver.
Hands-on operations consulting for manufacturers — grounded in the Toyota Production System and focused on measurable improvement, not binders on a shelf.
Operational Assessment
A structured on-site review of flow, scheduling, staffing, data, and daily management — showing exactly where your plant loses time and money, with a prioritized improvement roadmap.
Production Control & Scheduling
Constraint-based master scheduling, order launch and release rules, and real-time order visibility — so every department knows what to deliver, in what sequence, by when.
Process Data Capture
The shop-floor data most plants never collect — cycle times, miss reasons, order aging, downtime causes — captured simply and reliably, so decisions run on facts instead of anecdotes.
Dashboards & Real-Time Visibility
Where every order sits, which department holds it, and how long it's been there — live plant dashboards and hour-by-hour boards the whole floor can see and act on.
KPI Systems & Accountability
Metric definitions everyone agrees on — OTD, first-pass yield, productivity per labour hour — with cascaded objectives and tiered daily management that turn numbers into ownership.
Org Design & Capacity Planning
Floor org charts with defined spans of control, job descriptions rebuilt against real work, headcount models tied to demand, and skills matrices so cross-coverage is planned — not improvised.
Training, SOPs & Standard Work
Standardized work for every core job, TWI-style train-the-trainer programs, tiered operator certification with visible tracking, and hazard analysis built into every SOP.
What your floor looks like when the system runs it.
Not stock photos — the actual tools we build with your team: hour-by-hour boards, standardized work, and a daily management cadence that escalates problems in hours, not weeks.
| Hour | Plan | Actual | Status / Reason |
|---|---|---|---|
| 7–8 | 12 | 12 | On plan |
| 8–9 | 12 | 13 | +1 ahead |
| 9–10 | 12 | 8 | Kitting short — R04 |
| 10–11 | 12 | 12 | Recovered |
| 11–12 | 12 | 12 | On plan |
Every miss gets a reason code the moment it happens — so "why did it miss" produces data, not arguments.
One best way, written down — quality checkpoints and safety callouts built into the sequence, TWI-style.
A standing cadence with a defined escalation path, so nothing waits for the monthly meeting to get unstuck.
Toyota discipline, applied to your floor.
North Plant Consulting is built on Toyota Production System experience — standardized work, TWI-style job instruction, tiered daily management, and visual control, applied hands-on in real plants, not taught from a slide deck.
Our approach is system-first: when delivery slips or a department is drowning, the root cause is usually a missing process, not a missing person. We fix the system, then build the roles, training, and cadence that keep it running after we leave.
Talk to UsWhy clients choose us
- Toyota Production System & TWI background — methods proven for decades
- System-first: fix the process before touching the org chart
- Measurable results: on-time delivery, first-pass yield, productivity per labour hour
- Built to sustain — your supervisors and leads run it after we're gone
Keith Harasymiw
Not like every other consultant on the market.
Keith spent 25 years in manufacturing — 15 of them at Toyota Motor Manufacturing Canada, where he learned the Toyota Way. It was there that he started looking at manufacturing completely differently: building workstations that work not just for the person who designed them, but for anyone who runs them. Hunting for ROI in its smallest and largest forms. Adding value in the right spots, and cutting waste out of the wrong ones. Mathematically sound KPIs — and an insistence that the data behind them is actually correct.
Those are the key functions of a well-oiled machine. But the floor teaches you there's more to it: budgeting, scheduling, labour variances, training that's up to date and controlled, and systematically built SOPs and training manuals. Time spent on the floor in every role gave Keith the habit of questioning everything — is this the right way, for this plant, for this purpose?
A straightforward engagement process.
Listen
A no-cost intro call to understand your operation, your pain points, and what success looks like.
Assess
On-site or remote review of your operations, data, and processes to find the biggest opportunities.
Plan
A prioritized, practical improvement plan with clear owners, timelines, and expected impact.
Deliver
We stay engaged through implementation so improvements stick — and results show up in your numbers.
Let's talk about your plant.
Tell us a bit about your operation and the challenge you're facing. We'll follow up within one business day.