In 2019, we were planning a major expansion and consolidation from several small production, warehouse and storage facilities to two new buildings with more than 130,000 sf. In addition to planning the move, we also set the intent to significantly improve and streamline our distillery production and warehouse operations, in anticipation of major growth opportunities in the coming years. We quickly realized that we needed to engage the services of a consulting firm to help us map out and plan this transition. Kocer Consulting to the rescue! Dan and his team immediately began to learn all about our operations and quickly uncovered several process improvements that would significantly enhance our operational efficiency. They designed a comprehensive map for several of our critical processes, and worked with our architect team to build professional and customized layouts for the new buildings. The finished product provided our company with an impressive ROI from the savings we are realizing from the plan and process improvements.
Drew Kellerman, Vice President of Production
DP West LLC
We talked to CAMPS about our need to streamline our operations and put the right processes and systems in place and CAMPS recommended Kocer Consulting and Engineering. The people from Kocer were easy to work with and they listened to our issues and came up with excellent solutions to improve our operations, on schedule and within budget. Thanks to Kocer Consulting and Engineering we have reduced rework and handling, higher capacity, procedures in place and our operations are performing on a higher level with lower costs. I would highly recommend them to any manufacturer.
Jennifer Kohler, President
Pacific Rehabilitation Centers – Medical
Our administrative staff and I worked with the Kocer when we needed help mapping out our processes from front desk to admission to our heath care programs. We had many touch points and inefficiencies. The Kocer group helped us unravel the inefficiencies, figure out where we needed to make changes and was instrumental in helping us negotiate through our own companies politics. The result was a more streamlined process. I would highly recommend their consulting services and will use them again.
Regine Neiders, Ph.D, CEO
SPIO is a manufacturer and distributor of dynamic orthoses and compression clothing for children with special needs based out of Burien, WA. In early 2019 we enlisted the help of the Kocer team to assist us to plan our manufacturing and determine if we outsource or manufacture in-house. In addition we hired Kocer for designing and implementing a Quality Management System (QMS) based on ISO-13485 to better meet the requirements of the FDA and MDD. Dan and his team were very easy to work with, taking the time to assess and understand our needs in order to design a scope of work that would encompass the project. Throughout the project they met with us on an almost daily basis to update us on their work, ensuring we understood each aspect of the QMS as it was completed. They were thorough, detailed, and timely in their delivery. Their professionalism and service exceeded our expectations. In the event we would need consulting services again, we would not hesitate to reach out to Kocer Consulting and Engineering for assistance.
Brad Shatto, General Manager
Tri-Tec Manufacturing is an engineering-focused OEM of electro-mechanical actuators for the shipbuilding industry. Tri-Tec is bidding on a substantial project that would triple our sales if awarded. In anticipation of winning the bid, we hired Kocer Consulting + Engineering to help us with capacity analysis, resource planning, material flow improvements, and optimization of our facility in Kent Washington. Dan and his engineers provided us with an audit that resulted in numerous recommendations. Dan’s team was very knowledgeable with manufacturing processes and ERP systems, diligent, easy to work with, and came in within budget. We would have no hesitation in hiring Kocer Consulting again as the need arises.
Rob Dunn, Director of Operations
Legend Brands ERP Implementation and Operational Transition
We recently acquired a chemical plant and a new product line, and we hired Kocer Consulting + Engineering to help our staff to manage the transition and implement our ERP system for these new operations. Kocer played an important role in helping us to meet our tight six-month deadline. They facilitated a collaborative effort and involved everyone in the scheduling of the project, helped to track and monitor progress, provided support for documentation and mapping of the production and business processes and supported the testing and configuration of the ERP through completion. They worked closely with our internal PM and the entire management team and were greatly appreciated and respected by all. Both operations were successfully launched and operating with the new ERP on time and within budget. When we compiled the lessons learned survey from our staff at the end of the project it was very clear that the support from Kocer was a major contributor to our success. I highly recommend hiring Kocer Consulting + Engineering for managing and supporting ERP implementations and operational transitions. Russ Wilson, CFO
University of Washington Industrial & Systems Engineering
I am writing first and foremost to thank you for your service to the Industrial & Systems Engineering department. Your expertise as a board member as well as chair of the Strategic Planning subcommittee has been instrumental in shaping the progressive growth trajectory of ISE at the UW – thank you! I could not have done it without you.
Linda Boyle, Chair, Industrial & Systems Engineering, University of Washington
Romac Industries is a manufacturer of pipe fittings for the water works industry. We hired Kocer Consulting and Engineering to help us improve our Shipping, Receiving and Warehousing operations at our Headquarters in Bothell Washington. Dan and company provided us with an audit that resulted in 40+ recommendations for improvement in our processes, layout and equipment. These best practice improvements are just what we need and will have a significant, positive effect on our operations. Dan came in on time and within budget with his quote and was very pleasant to work with. He and his group were professional, knowledgeable and very flexible in working with us and around our busy schedule. We will most definitely use Kocer Consulting and Engineering in the future as the need arises.
Todd Colyer, Director of Operations
Osprey Packs, Inc.
We partnered with Kocer Consulting + Engineering to review our Distribution Center capacity and to review our current processes and suggest solid process improvements. Dan Kocer and his team more than met our expectations by delivering a complete and thorough analysis. They met with our staff and took the time to understand our operation from top to bottom and were able to provide actionable suggestions all through the process. I see no reason why we wouldn’t continue to work with Dan Kocer and his team in the future.
Larry Bratton, Director of Distribution
I would highly recommend Kocer Consulting + Engineering! We worked with Kocer Consulting in 2016 with a goal to improve to our Manufacturing Division and move to more modern manufacturing techniques (Lean, Six Sigma, 5S projects). Our work with Kocer started with an overall assessment of our manufacturing operation and from there they made recommendations on three key areas they felt would give us the best our best gains in efficiencies and processes. The three area they recommended we focus on were: Quality, Cutting & Machining and Welding. We previously had no formal tracking program in place for quality issues which they assisted us in implementing.
The results of initiating quality tracking has allowed us to do a much better job in determining which areas we have quality issues in and has allowed us to catch defects in areas like welding prior to painting and assembly which has saved us significant dollars. By formally tracking vendor quality has also helped us to better manage our vendor relationships and helped us determine if we need to consider making a change in that area. These quality improvements have certainly made us more effective. From our work with Kocer Consulting we learned to build product in smaller batches which has helped us cut down on our work in progress and inventory dollars.
Through the lean training our welding department came up with more efficient ways to lay out the department to increase product flow thus saving more time. With Kocer’ training and guidance, our people set up an area for all cut Department finished jobs to be placed and labeled so welding can retrieve these components without contacting a supervisor. These are just a few examples of some of the work we did with Kocer Consulting. They were great at keeping our management team informed with their progress by providing us regular reports after each training section. They really helped us implement a better culture for continuous improvement and I would highly recommend Kocer Consulting. The work we did with Kocer has given us a great beginning as we move our business to a more modern manufacturing approach.
Dave Rankin, CEO and Owner
Peripheral Visions, Inc.
Kocer Consulting + Engineering has provided us with a strategy to improve our company. Their assessment of our operations and current ERP system was very thorough and included many ideas to be more profitable. The benefits of each improvement opportunity was fantastic and they provided a roadmap for how to implement. In addition, they were conscious of our price target and timeline. They were able to research and secure a significant amount of grant funding from the State of Washington to pay for improvements. I would highly recommend their services and we are planning on working more with them in the future.
Kent Laverdure, President
The Kocer Consulting + Engineering software expert identified ERP alternatives and recommendations that were much better than anything we had considered. The Kocer team captured our requirements and picked the system that best fit our needs, in an efficient, collaborative and professional manner. The end result of Kocer’s help was an ERP system with a faster implementation, more robust functionality at a significantly lower cost. I recommend Kocer Consulting + Engineering to other manufacturers who need to select and implement a new ERP system.
“After recognizing we needed a change in our processes and practices Thermaline turned to Kocer Consulting + Engineering for help. The KC+E team had a “hands on“, “part of the team“ approach. They worked side by side with every member of the Thermaline transition team, both in the office and rolling up their sleeves with the shop floor personnel.
Not only did KC+E guide us on our lean journey but played a vital role in changing our cultural landscape. They fostered creativity and made sure everyone had a clear understanding of our new processes.
As a result of working with the KC+E team we were able to transform to lean manufacturing in a short period of time and quickly reach our goals.
a) Deliver products to customer in 3 days – previously 45-50 days
b) Improve profitability – 2.5% to 12%
c) Increase capacity without hiring more people
d) Decrease overtime and eliminate manufacturing chaos
e) KPl’s that make sense
f) Create a visual factory floor, reduce set up times and implement a 5-S program
g) “Buy in“ from EVERY employee
KC+E did not have the typical “do it my way“ consulting approach. They were a pleasure to work with and I would highly recommend the services of KC+E.“
Leon Sanders, President & CEO
Kocer Consulting + Engineering embraced our project whole-heartedly and dug into all issues from all angles, beginning to end and top to bottom. They came back with great recommendations and even found cost-savings in areas beyond the original scope of the project. They approached the work with enthusiasm and a strong sense of accountability. The savings we found as a result of their discovery more than paid for the original investment itself and everyone was very happy with the results.
Megan Evert, Director of Operations and Sales Support
H.R. Spinner Corp.
Our company hired Dan Kocer and others in his firm to help us design new layouts for all our facilities. This was critically important to us because we purchased a new warehouse that doubled our footprint and we wanted to gain efficiencies across our company, not just increase our capacity. In conjunction with the work that Dan did to help us become Lean in our warehouse design and layout, he also helped us with our transportation practices and with our initial efforts to ultimately employ warehouse management systems software.
Although Spinner has been in the warehousing and distribution industry for almost 100 years, our people felt that Dan’s insights helped us improve our operations. We are better now than we would have been without the work that Kocer Consulting did for us.
I personally have no reservations in recommending Dan to anyone who wants to break from “that’s how we’ve always done it“ to utilizing best practices across their operations.
Terie G. Ellis, CFO
During their consultation agreement, Kocer Engineering helped Chinook Enterprises by identifying areas of duplication and designing processes to eliminate waste, reviewed our job layouts and material flow, then identified efficiencies to improve them. These changes will cut our job overhead cost and better focus our employees while eliminating errors. Kocer staff also reviewed our ERP system and suggested several different ideas to gain value by better configuring reports to provide more accurate, timely information. In a competitive, production atmosphere where costs, delivery and accuracy are critical, their work was invaluable.
Vulcan, Inc./EMP Museum
Kocer Consulting and Engineering worked with us in developing a shop equipment layout for a new facility. Their help and expertise lifted a burden at a time when our employee’s priorities were focused on what they do best, rather than spending time on things like floor plans, layouts and work flow. All of their suggestions were creative and concise. The overall experience turned a drudgery into a pleasure.
Absher Construction Company
Kocer Consulting + Engineering helped us to get our arms around a very complex high-school expansion and renovation project. KCE lead us through the pull planning process with all of our subs. This resulted in much more organized project and an earlier completion date.
John Vandervate, LEED AP, Project Manager
Sunlight Supply is a high-growth, successful manufacturer and distributor of horticulture and aquarium supplies, with ten distribution centers across the nation and two manufacturing facilities in Washington State. When we decided to embark on implementing our newly purchased ERP system we needed outside expertise to help configure the system to mesh with our operational and business needs and introduce distribution and supply chain best practices. We hired Kocer Consulting and Engineering because of their reputation, experience and success in the industry. This proved to be a very good move on our part. Kocer’s people quickly gained the respect of our executives and our staff, learned and mapped out the details of our operations, identified best practices to improve our customer service and distribution, determined the capabilities and pitfalls of our new system, provided a road map, and guided the configuration to help us get the most from our investment. They discovered some “holes” in the capabilities early on, and provided solutions to fill these holes, including voice picking and paperless Putaway. During the execution phase they demonstrated a much-needed sense of urgency as they trained our people at all eleven sites across the nation, prepared each site for go-live, tested the software and provided diagnostics and trouble-shooting to quickly and intelligently solve the issues. They provided a detailed document that gives step-by-step procedures on the new best practice operations and best use of the system and reports. This proved to be very beneficial to our efficiency and customer order accuracy. After go-live they played a very important role in diagnosing and troubleshooting software bugs, and they audited each of our plants to ensure that the standard procedures were being followed. They also helped us to set up our new cycle counting schedule and procedures, and trained all sites to perform this. They provided weekly status reports, and are organized in their project management and very diligent about passing their information and knowledge on to our staff. Kocer’s team worked well with our team and we appreciate their straight-forward answers to our questions. I recommend Kocer Consulting and Engineering to any company who plans to make changes to improve their operations and systems.
John Bateson, CFO
Progressive International Corp.
Progressive International and Kocer Consulting & Engineering have partnered since 2003. Dan has extensive experience in distribution/warehouse operations process improvements and systems engineering. He has provided valuable consulting and engineering services in our identification of required operational improvements and our detailed search and assessment of a WMS. Dan will play an instrumental role in our project development and implementation. We have worked with several large consulting/engineering firms but we have found Dan’s flexible hands-on approach to understanding our operation and his ability to customize to our needs to be very refreshing and extremely valuable.
Patrick J Klein, VP Logistics
National Sign Corporation
I would like to thank you for and your firm for the professional service that you have provided National Sign Corporation over the last 3 years. Your team has brought a consistent level of professionalism and expertise to the various tasks that we have authorized.
I was very impressed with the quality of work that you performed, and I know all of our employees valued your contributions. Your assistance in getting the involvement of our entire operations staff was invaluable.
Even today we still see the value of your consulting work in the daily incremental cost savings that continue to be seen in some of the processes that we setup. I look forward to having an opportunity to retain Kocer Consulting and would recommend your services without hesitation.
Timothy Zamberlin, President
Berntson Porter and Company LLC
Dan gave a fun interactive presentation at our firm which focused on Lean Manufacturing. I enjoyed watching my coworkers simulate a manufacturing line and seeing the impacts of process improvements. Great hands on approach to teaching!
Amanda Goodman, CPA
Cutter & Buck
I want to let you know that I appreciate the valuable solutions and insights your team has provided in the seven years we have worked together. Your approach of blending best in class engineering with process understanding has created tangible improvements in our Renton operation. Your consulting recommendations led to low cost, high impact projects we could implement quickly for cost reductions. In addition, your top to bottom review of our fulfillment model has prepared us with plans we can implement to support future growth. Finally, your willingness to coordinate various site visits for my team allows us to stay current on the latest technologies and management ideas in our industry. Thank you for your continued partnership.
Rick Martinez, Director of Distribution
Sunlight Supply, Inc. / National Garden Wholesale
I would like to let you know that working with Dan Kocer and his team has been a great experience for me and the company I work for Sunlight Supply. We developed a partnership with Dan’s company almost two years ago. His team was employed to assist us with determining best practices for our distribution centers. He spent time working with our management team and offered assistance in determining the best operating system for our needs in distribution.
We spent the first few months gathering information and determining what type of operating system would work best for our application in the warehouse. Dan spent numerous hours researching several different warehousing operations and interviewing companies to help determine the direction we should pursue.
Once we all agreed to pursue a voice-picking type of system, Dan and his team immediately began to look into operations that were currently using it. He then researched the different companies who offered the systems and arranged for our company representatives to visit several different operations and ask questions about their experiences with a voice picking system.
When a decision was reached as to whom we were going to choose, Dan had already done the necessary research to determine all the necessary equipment we were going to need. He itemized everything and began to shop for the best value for our company. When we were ready to purchase this system, he had already begun a leverage plan to get the price pricing available. He helped us to determine a fair offer with expectations from the vendor.
After purchasing the new system, Dan quickly assembled a team to become experts with not only the voice system, but the newly purchased operating system our company purchased before his arrival. His team became the necessary trainers to teach our management staff the inner workings of both systems and how they were going to work (or not work) through several hours of testing the two systems.
Our relationship developed into a true partnership and they took us to a level of operations that exceeded my expectations. Everyone on his team was willing to do whatever it took to get through the challenge on the table.
This is a very brief description of their work…I would absolutely call them in the future to help with any of our future needs!!! Please feel free to contact me for additional information.
Glen Morrison, National Director of Warehousing Operations
Bellegrove Medical Supply
I want to thank Dan and his team at Kocer Consulting and Engineering for bringing our company up to standard with the best practices in distribution. Our company is small but growing and did business the way we always had. Dan did a thorough investigation or our practices, worked with our current software and implemented a plan within our means to bring us forward. He also designed and oversaw our move to a new facility. His company was certainly the right fit for us. He has left us in a place where we can continue to grow, be more profitable and compete by decreasing our overhead.
Mark Holzemer, President
Atlas Supply, Inc.
This is to say “thank you” for the help and recommendations you provided in connection with the Purchasing and Inventory Management study you performed for our company in July, 2007. Focusing on our fill rate problem, you and your team provided valuable, concrete insights into the issues and a range of recommendations we are currently following through on.
Specifically, I appreciated your straightforward and systematic approach from start to finish—from project proposal and definition through final invoicing. Your team had a sense of urgency about attacking the problem and you were able to complete the project in a shorter time frame than I anticipated and within budget. Your folks did a thorough job of understanding our operations and highlighting where the opportunities existed in the various processes. Communication was good throughout the study and I was confident at the end that we had an opportunity to evaluate a number of alternatives that ultimately resulted in cost-effective recommendations.
Thanks again, Dan, and I would not hesitate to recommend your services to any company looking to analyze and improve their operations and efficiency. Likewise, we would definitely use your services again in the future as needs arise.
John Ittes, President
Da Vinci Gourmet, Inc. – One of Washington’s fastest growing private companies
Dan got his hands dirty working on the floor with my team then was able to explain the concepts of modern inventory management so that we could all understand where our gaps were and what needed improved. Dan saved us real money by improving our inventory losses and by reducing the amount of time we spent counting our stock. The best part was that our month end closings were accurate and completed in two days. Our accounting staff loved that!
Rico Yingling, COO
The Boyd Group, Inc.
Kocer Consulting and Engineering developed, presented and lead us through the implementation of facility design changes and operational process improvements, as well as systems, equipment, and inventory management changes. These changes did result in improved performance in many of our performance metrics. Kocer Consulting and Engineering also fit in well with our management team, and the “lean thinking” approach allowed us to accomplish these improvements with minimal capital expenditure. In summary, Kocer Consulting and Engineering proved their “bottom-line” value to our organization and we are pleased to refer them to other companies. We would not hesitate to use them again if needed.
W. Brock Bulbuck, Senior Vice president and COO
King County Housing Authority
We hired Kocer Consulting and Engineering at KCHA with the objective of eliminating waste in our Section 8 inspection process. Kocer reviewed our current processes, identified non-value activities, and provided a list of recommendations to streamline our process. They did a very thorough job interviewing our staff by whom they were well received. The flowcharts they provided were easy to understand and comprehensive. We have recommended their firm to several other housing authorities. We plan on implementing many of their suggested recommendations. I was extremely satisfied with the quality and timeliness of Kocer’s work.
Mike Reilly, Director, Housing Management
Kent Chamber of Commerce
The President’s Leadership Award is presented to a member who has demonstrated exemplary leadership to accomplish the Chamber’s vision, mission and strategic goals. I am delighted and honored to present this award to Dan Kocer, owner of Kocer Consulting and Engineering. Dan has been a member of the Chamber for five years. He is an Officer of the Board, serving as the Vice President of the manufacturing/supply chain division. In 2005, he was instrumental in developing our successful “Best Practice Tours.” I have appreciated Dan’s forward thinking and thoughtful input, and also his commitment to the success of the Chamber’s manufacturing and the manufacturing industry. Dan has contributed greatly to our success and is an exemplary member of our team.
Donna Reinke, President, Kent Chamber of Commerce, VP, Washington Mutual Bank
Write-up for the Cavatappi Wine Project
After reviewing the project requirements, WMS teamed with Kocer Consulting and Engineering, an experienced consultant in warehouse design and layout, to provide a new facility layout. The resulting layout allowed for efficient flow of materials, maximum storage capacity for the new building, modular, easy-to-understand location scheme, and room for future expansion.
Washington Manufacturing Services
University of Washington
On behalf of the GTTL Studies, I would like to thank you for sharing your time and knowledge with our students this spring quarter. Your comments and insights provided and excellent supplement to the information they gathered from their readings and class lectures.
Greg Shelton, Managing Director, Global Trade, Transportation, and Logistics Studies
Dan and I worked very closely together whilst I was at Rushforth Construction, Inc on several industrial projects. I enjoyed working with Dan and the other members of his team because we were all able to contribute ideas to make the project a success. This collaboration resulted in some very good output to the benefit of the client. Kocer Engineering is a first-class professional team.
Senior Project Manager
My company has worked with Kocer Consulting on a couple of projects. They have been instrumental in their advice and guidance to implement a couple of different projects we were working on. They were very accountable to the objectives and timeframe that were agreed on. We were very pleased with the outcome for both of these projects.
Lisa Chissus, President & Owner
Kocer Consulting + Engineering helps companies become more profitable and sustainable by developing and implementing improvements to their operations and systems, and planning for the future.