CatLuc Consulting — United States

TRANSFORM.
AUTOMATE.
ACCELERATE.

We drive measurable business turnarounds through the Theory of Constraints and the Toyota Production System — combined with cutting-edge industrial automation: laser cutting, CNC, welding, and machine vision.

3X
Avg. Throughput Gain
60%
Waste Reduction
90D
Rapid Turnaround

OUR SERVICES

From strategic business consulting to hands-on industrial automation — end-to-end solutions that create lasting competitive advantage.

📈
Business Turnaround

Rapid diagnosis and transformation of underperforming operations. We identify the core constraints holding your business back and build a clear roadmap to breakthrough results.

TurnaroundP&L ImprovementChange Management
🔗
Theory of Constraints

Using Goldratt's TOC framework, we expose hidden bottlenecks and apply the Five Focusing Steps to achieve maximum throughput with minimum investment.

TOCDrum-Buffer-RopeCritical Chain
⚙️
Production Systems

Lean and flow-based production system design tailored to your industry. We optimize layout, material flow, scheduling, and workforce planning for peak efficiency.

Lean ManufacturingFlow DesignKaizen
🤖
Industrial Automation

Turnkey automation solutions integrating robotics, PLCs, and HMI interfaces to increase speed, precision, and reliability on the shop floor.

RoboticsPLC / HMISystems Integration
🔆
Laser & CNC Systems

Selection, installation, and optimization of laser cutting machines and CNC machining centers. We maximize OEE, reduce setup times, and improve cut quality.

Laser CuttingCNC MachiningOEE Optimization
👁️
Machine Vision & Welding

Advanced machine vision for automated inspection and quality control, combined with robotic MIG/TIG and laser welding automation integration.

Machine VisionRobotic WeldingQuality Control
Toyota Production System

SHINGO VSM & LEAN ANALYSIS

We conduct a deep analysis of your factory using the Shingo VSM — Shingo Value Stream Map, the cornerstone tool of the Toyota Production System created by Shigeo Shingo — making every loss, waste, and inefficiency visible across the entire production flow.

From the VSM, we apply Pareto Analysis to rank and prioritize the biggest losses, focusing energy exactly where it delivers the fastest and most significant results.

Our diagnosis uncovers the hidden killers of operational performance:

  • Production Synchronism Failures — steps out of pace causing pile-ups and starvation downstream
  • Waiting Losses — operators, machines, and materials waiting for each other
  • Inefficient Layout — unnecessary movement, long transport routes, poor workstation organization
  • Overproduction & Excess WIP — producing more than needed, hiding real problems
  • Rework & Defects — quality failures that consume capacity and destroy lead time

Lead Time Reduction is one of the most critical business metrics — it determines customer responsiveness, working capital efficiency, and true competitiveness. Our VSM-driven approach consistently delivers 40–70% lead time reductions within the first engagement.

🗺️

Current State VSM

We map the entire value stream as it exists today — every step, every wait, every handoff — from raw material to shipped product. All waste becomes visible.

📊

Pareto Loss Analysis

We quantify every loss in time, cost, and capacity, then rank by impact. The top 20% of problems cause 80% of the damage — we go there first.

Rapid Improvement Events (Kaizen)

Focused 3–5 day workshops targeting the highest-priority losses. Immediate, measurable results — not months of planning before action.

🔄

Flow & Synchronism Design

We redesign production flow to eliminate waiting and synchronize all steps to the customer's takt time — smooth, continuous, waste-free.

📐

Layout Optimization

Physical factory layout redesigned for minimal movement, logical flow, and visual management.

🎯

Future State VSM

We design the ideal future state — a concrete, actionable blueprint with dramatically reduced lead time and maximum value flow.

40–70%
Typical Lead Time Reduction per Engagement
Our Automation Philosophy

DON'T AUTOMATE WASTE.
AUTOMATE LEAN PROCESSES.

Most companies rush to automate — and end up spending millions to do the wrong things faster. We do it differently.

01
🗺️
Map & Expose
Shingo VSM reveals every loss and broken flow in your current process
02
✂️
Simplify First
TOC + Lean eliminate waste, synchronize flow, and streamline to the leanest possible form
03
🤖
Then Automate
Only now we automate — a clean, lean, optimized process — multiplying efficiency, never locking in waste

Very few companies in the world apply this sequence. Most automate first — and permanently embed their inefficiencies into expensive machines. We automate lean processes. Never losses.

Theory of Constraints

THE TOC APPROACH

01

Identify the Constraint

We map your entire operation to find the single bottleneck limiting system throughput — the weakest link in the chain.

02

Exploit the Constraint

Before adding resources, we extract maximum performance from the constraint with zero additional investment.

03

Subordinate Everything Else

All other processes align to support the constraint. We stop optimizing non-bottlenecks that create false efficiency.

04

Elevate the Constraint

When needed, we invest precisely — automation, capacity, or capability — to permanently break the bottleneck.

05

Repeat & Accelerate

Constraints shift as performance improves. We install a continuous improvement culture that sustains every gain.

Throughput Analysis
FIND THE
BOTTLENECK
Intake
85%
Processing
72%
⚠ Welding
31%
Assembly
68%
Inspection
79%
Shipping
90%
Constraint identified: Welding at 31% is throttling the entire line. Fixing this single point unlocks full system throughput.
🧭 CatLuc Methodology

The Financial Compass

Developed by CatLuc through years of application across multiple industries

A methodology developed by CatLuc that connects TOC Throughput Accounting to Product Engineering and Process Engineering — establishing the missing link between the factory floor and financial control.

💰
True Product ProfitabilityWhich products generate the most real gain through the constraint — not just accounting margin
🏭
Optimal Product MixThe ideal mix to maximize total throughput given current capacity constraints
📈
Pricing & Sales StrategyGuides pricing and sales priorities based on real constraint economics
Applied across metal fabrication, automotive, industrial equipment, and electronics — the Financial Compass consistently reveals that the most profitable product mix is not what traditional cost accounting predicts.
Who We Serve

TARGET INDUSTRIES

Deep expertise across manufacturing and industrial sectors with proven methods that translate across verticals.

🏭
Metal Fabrication

Laser cutting, welding, CNC machining, and press brake operations.

🚗
Automotive

Assembly lines, stamping plants, tier suppliers — rapid throughput improvement.

✈️
Aerospace

High-precision manufacturing and inspection automation for AS9100 environments.

🔩
Industrial Equipment

Custom machine builders, OEMs, and industrial assembly — designed for flow.

🏗️
Construction Products

Structural steel, modular building, and prefab manufacturing optimization.

Electronics Mfg.

PCB assembly, electromechanical integration, and vision-guided automation.

Our Differentiators

WHY CHOOSE CATLUC

01

Business + Technical Expertise

Rare combination of strategic consulting and hands-on industrial automation. We don't just advise — we implement.

02

Simplify Before You Automate

We never automate losses. First we eliminate waste with Shingo VSM and TOC, then we automate lean, optimized processes.

03

Proven TOC + Toyota System

Two of the most powerful operational methodologies combined — delivering measurable results in 90 days or less.

04

The Financial Compass

Our methodology connects the factory floor to product engineering, process engineering, and financial control — the missing link most businesses never find.

05

Technology-Agnostic

We recommend what's right for your situation — laser, CNC, vision, robotics — not what we're paid to sell.

Every system has a constraint. Every constraint is an opportunity. We exist to turn your biggest limitation into your greatest competitive advantage.
CatLuc Consulting — Core Belief
Get In Touch

LET'S TALK ABOUT
YOUR CHALLENGE

Tell us about your operation and we'll get back to you within 24 hours. No commitment required — just a conversation.

Reach us directly contact@catlucconsulting.com