Featured Case Study

From prototype chaos
to 30,000 units/month

Blast Motion sports sensor attached to batting glove 2017 MLB World Series
Blast Motion · Sports Wearables

How I scaled a sports wearable startup from prototype chaos to a manufacturing operation ready for volume — in time for its product to land in the hands of the athletes who won the 2017 MLB World Series.

Brought in as a consultant. Stayed on as Director of Operations. The story of how the operational foundation actually got built — what was broken, the three-pillar approach I deployed, and the numbers that came out the other side.

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Foundation Case Study

Engineering the
Quarter Back

Tier-1 Hardware OEM · Earlier-Career Foundation

How I closed a 55-point shipment gap in a single quarter — and the four-lever framework that translates from enterprise hardware ramps to any startup moving from prototype to production.

Conservative post-2008 forecasts had given away SMT capacity. A critical long-lead Broadcom BGA was locked out by a lead-free vs. leaded mismatch. $24.5M of quarterly revenue was at risk. Recovery came from working four levers in parallel — sourcing resilience, ME-led problem solving, CM trust architecture, and data-validated test compression.

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PCBA close-up — hardware manufacturing recovery +55-Point Recovery · One Quarter
Proof of Work

Selected engagements

Expertise spanning
Hardware from concept to production — built and scaled consumer electronics from early development through volume contract manufacturing
Chipset and strategic supplier relationships — developed key partnerships with silicon and component suppliers that unlock faster access and better terms
PLM and operations systems — implemented Arena PLM, NetSuite, and 3PL integrations to build scalable, auditable production backbones
Manufacturing yield and test — improved first-pass yield from 76% to 98% through test process redesign and CM execution improvement
Full workstream management — mechanical, silicon, plastics, tooling, and assembly across Asia and global supplier networks
Sports sensor — the product
01
Concept to Production

Sports Sensor: Prototype to Contract Manufacturing

Built the full procurement and manufacturing infrastructure for a consumer sports sensor — from initial supplier relationships and PLM/BOM discipline through prototype assembly and full CM scale-up.

Built supplier relationships → PLM → CM volume production
Factory test station
02
Cost Reduction

Negotiation-Led Cost Reduction Across a Device Portfolio

Drove multi-year cost reduction across a consumer device portfolio through commercial negotiation, supplier consolidation, and contract restructuring — balancing next-gen requirements with operational and supply chain tradeoffs without sacrificing performance.

Negotiation strategy → portfolio-wide cost reduction
SMT control station
03
Product Quality

Driving Product Quality Through Manufacturing Discipline

Partnered with engineering and CM teams to improve product quality at scale — through test process redesign, manufacturing execution discipline, and tighter accountability across supplier partners. Lower scrap, fewer rework cycles, and meaningfully reduced production risk.

Test redesign + CM discipline → step-change in quality
Integrated Operations Stack
04
Operations Infrastructure

Procurement Backbone via NetSuite, Arena PLM & 3PL

Built the procurement and operations backbone for a scaling hardware company using NetSuite ERP, Arena PLM, and 3PL integrations — creating the systems infrastructure needed for repeatable, auditable production.

NetSuite + Arena PLM + 3PL fully integrated
SMT line operators
05
Spend Management

$168M in Annual Spend. Run with Discipline.

Owned the procurement engine behind a hardware portfolio at scale — $168M in annual supply chain spend, hundreds of suppliers, and the on-time delivery discipline to keep production moving. Enterprise-grade execution, hands on every dollar.

$168M spend managed · 96% on-time delivery
Engagement Types

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Diagnostic sprints, project-based engagements, and ongoing fractional advisory — structured to match where you are and what you need to solve.

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