CASE STUDIES

CASE STUDY 2: PROCESS INNOVATION FOR SHAPED TRIM INSERTS

A major automotive customer had been relying on a competitor, to produce shaped trim inserts for a seat. But the results were far from ideal — three-month lead times, high costs, and inconsistent quality that created ongoing headaches. Their process was not only slow, but also expensive and riddled with inconsistencies that led to frustration for both the plant and the customer. The customer needed a more reliable, cost-effective partner who could not only deliver faster — but also eliminate the quality variations holding their production back. The current supplier’s approach simply wasn’t sustainable.

How I Helped:

I developed a presentation outlining a streamlined fixturing process that could standardize insert production from start to finish. We pitched the plan to our plant in Mexico, and within one month — not three — the team had successfully implemented it. I then traveled to the plant, reviewed their results, compared it against the original proposal, and fine-tuned it for even better consistency.

Big Win:

What once took months now took weeks — and with significantly less waste and variation. The customer saw improved quality, faster output, and lower costs. They were thrilled. The result? Instead of feeling frustrated and stuck, the customer now had complete confidence in our team. We didn’t just take back the business — we proved we could deliver excellence, fast. A dramatic cut in lead time from 3 months to just 1. Not only did we win the business back, but both the internal team and customer were thrilled with the quality, speed, and cost savings of the new process.

CASE STUDY 3 : BUILDING CRAFTSMANSHIP INTO THE SEAT ASSEMBLY PROCESS

Our manufacturing plant was under pressure to improve the craftsmanship of seat builds — a quality that was critical to standing out in a highly competitive automotive market. But they were struggling. Technique varied from person to person, and onboarding new employees felt like starting from scratch every time.

Without a clear, repeatable process, the plant couldn't maintain consistent build quality. Training was inefficient, tribal knowledge was getting lost, and quality suffered. They needed a better system — one that captured expert-level technique and scaled it across the workforce.

How I Help:

I stepped in to bring structure and strategy to the challenge. Leveraging my experience in process planning and visual communication, I collaborated with our offshore team to design a visual trim build sequence that clearly mapped out the critical steps.

We created a detailed drawing that highlighted key craftsmanship checkpoints. This wasn’t just a static document — it became the foundation for a repeatable training system. We recommended video monitors at workstations showing real-time demonstrations of those techniques, helping both master builders and new hires align around a common standard.

Big Win:

The result? A more disciplined, visual approach to building seats that elevated craftsmanship, reduced training time, and gave the plant a repeatable system to reference and improve on over time.

The team shifted from improvising builds to confidently executing a proven process. It’s not just about building seats anymore — it’s about building pride in the process.

CASE STUDY 4: ELECTRIC MOTORCYCLE CITY COMMUTER PROJECT

Alex, a design-savvy entrepreneur, noticed something on his daily commute: more and more riders ditching cars for nimble, stylish eBikes. It wasn’t just a trend — it felt like a movement. But was it just a city bubble, or the start of something big?
He had questions. No clear data. And too many ideas.

How I Help:

In this project, I stepped into Alex’s shoes — diving deep into the electric vehicle landscape, understanding the rise in market size of Ebikes. Through market research, I uncovered growth trends, behavioral shifts, and untapped segments ready to be explored.

Big Win:

The result? A crystal-clear understanding of where the market is headed — and a strategic vantage point on how to ride that wave.

CASE STUDY 5 : EXPLORING INNOVATION IN COMPUTER MICE WITH RETRO THEMES

Dylan, a digital artist and vintage collector, was browsing online for gear to match his retro-inspired desktop setup. He had the neon lights, pixel-style wallpaper, and synthwave playlist — but his mouse? Boring. Generic. Soul-crushingly modern.

He thought: “Why doesn’t anyone make hardware that feels like the 80s but works like 2025?”

How I Help:

This personal project was born from that same frustration. I saw an opportunity to blend 80s TV nostalgia with modern product usability — creating a mouse that feels like Knight Rider, looks like a VHS tape, and performs like a pro tool.

I began sketching out ideas inspired by shows like Airwolf, Knight Rider, and Tron — and translating those bold aesthetics into product forms.

Big Win:

An idea that wasn’t just functional — it was emotional. It didn’t just work — it sparked memories.