Solid-wood manufacturing · furniture · domestic + export
QMS, built & certified — one fiscal year.
Quality-management system designed, documented, and through external audit inside a single fiscal year — without halting production. The output is a plant that holds the line whether the head of operations is in the building or on holiday.
The brief, on arrival, was "certify the QMS." The diagnosis came back with a different one: the QMS was the symptom; the underlying issue was that the operation's quality logic lived in one head — the senior production manager's — and was therefore unportable, unauditable, and one resignation away from collapse.
The engagement ran the QMS build as the documentation pass that surfaced — and then encoded — the quality logic the operation had already been running. Documentation was the deliverable; the system was the by-product.
What changed.
- Yield on lumber input rose 2.5 percentage points — translated into a measurable raw-materials cost reduction at the engagement's metric review.
- Claim rate dropped from 4.1% to 0.5% — driven by the lot-tracing and inspection gates introduced during stabilization, then formalized during the QMS pass.
- Productivity rose 20% on the same headcount, primarily from a re-ordered shift hand-off and standard-work documentation on the top five recurring tasks.
- Revenue lifted ₽2B over the engagement window — credited to the operation by the client's own CFO on the post-close review.
What didn't.
Production never stopped. The plant ran through the engagement at its full annual cadence. Headcount on the floor stayed flat. The senior production manager — the one whose memory had been the QMS — was promoted into a role the documented system finally let him take on.