AI-Assisted Quality Engineering · Lean Six Sigma · Continuous Improvement
Closed Loop Consulting partners with manufacturers and industrial operations to eliminate defects, reduce waste, and build lasting quality systems — backed by 30+ years of combined hands-on quality and operations experience in high-reliability manufacturing.
What We Do
Patrycja brings quality engineering, standards, and statistical analysis depth. Dennis brings decades of operations leadership, GD&T expertise, and continuous improvement results across global manufacturing. Together they cover the full improvement lifecycle.
Design, implement, and certify QMS frameworks meeting the most demanding customer and regulatory standards in aerospace, automotive, and industrial manufacturing.
Measurable, sustainable improvement through disciplined DMAIC methodology, Value Stream Mapping, and Kaizen events — delivered by certified Black Belts with proven multi-million dollar impact records.
Senior operations leadership — improvements in production, supply chain, and organizational design that deliver measurable cost and efficiency impact and hold long after the engagement closes.
Good quality decisions start with good data. We build the dashboards, statistical models, and tracking tools that turn raw process data into something your team can actually act on — using the platforms you already own.
From Power BI quality dashboards to Minitab capability studies and SPC control systems, we help you see variation, catch problems early, and prove improvement with numbers — and we increasingly use generative AI tools to do that work faster.
Our Process
Every engagement follows the same four-phase process — from identifying the true root cause to verifying that the improvement holds. Nothing is left open.
On-site gap analysis, process mapping, data collection, and baseline measurement. We see your operation as it actually runs — not as the SOP says it should.
Root cause identification using DMAIC, Fishbone, 5-Why, FMEA, SPC, GD&T review, and Minitab statistical analysis. Data-driven conclusions, no assumptions.
Structured improvement execution with your teams. Control plans, standard work, digital systems, and change management built for durability and operator ownership.
Post-improvement measurement, process capability confirmation, and audit readiness verification. The loop is not closed until the numbers — and the auditors — prove it.
Industries Served
Our principals have held senior quality and operations roles inside the industries we serve. We understand your standards, your customers, and your cost pressures — because we have worked inside them.
AS9100 Rev D, FAA compliance, first article inspection, GD&T interpretation, and precision manufacturing QMS design.
IATF 16949, VDA 6.3, PPAP, APQP, OEE improvement, and Tier 1 / Tier 2 supplier quality development including PPM reduction to near-zero.
High-power connector quality, EV supply chain containment, defect reduction programs, and electro-mechanical assembly quality systems.
TL9000 compliance, zero-defect programs for Verizon, US Cellular, and wireless infrastructure manufacturers across metal fabrication and composite manufacturing.
ISO 9001 implementation, warehouse operations, inbound logistics quality, compressor and refrigeration assembly CI programs.
Multi-site management across North America, Latin America, Europe, China, Mexico, Brazil, and India — P&L, plant consolidation, and M&A integration.
The Principals
Closed Loop Consulting pairs a seasoned operations executive with a dedicated quality engineering specialist — two professionals who have spent their careers inside the quality and operations functions of the industries they now serve.
Patrycja brings over 15 years of quality engineering experience across aerospace, automotive, and electronics manufacturing. She has worked in QMS implementation, supplier quality development, Six Sigma project execution, and process capability improvement at scale. She is skilled in Power BI dashboarding, Minitab statistical analysis, and SPC, and applies GD&T and CMM knowledge to support precision manufacturing clients from blueprint review through measurement validation. She actively uses generative AI tools to accelerate documentation, analysis, and continuous improvement work, bringing a modern, efficient approach to traditional quality engineering. She holds a B.S. in Industrial Management & Applied Engineering and an M.S. in Quality Engineering Management, both from SIU.
Dennis is a C-suite operations executive with 30+ years leading global manufacturing, lean transformation, and business initiatives totaling over $200M in documented financial impact. His experience spans VP and Director roles at Electri-Flex, Amphenol, BorgWarner, and Ingersoll Rand across automotive, aerospace, telecom, biometric, and industrial sectors. Fluent in English and Spanish, he has managed multi-site P&L operations across five continents with $300M revenue responsibility. An active engineering faculty member at SIU and former instructor at College of DuPage and TMA, he teaches GD&T, CNC, blueprint reading, and manufacturing processes — a level of technical depth that is rare at the executive level.
By the Numbers
Selected aggregate outcomes from Patrycja and Dennis’ combined careers — the same methodologies, tools, and discipline brought to every client engagement.
Case Studies
Representative engagement outcomes across quality engineering, operational excellence, and AI-enabled CI disciplines.
End-to-end containment-to-closure quality program for a high-power EV connector product line. DMAIC root cause analysis, GD&T-informed dimensional review, process capability improvement, and supplier corrective action across the supply chain.
Comprehensive quality and operations improvement across metal fabrication, clutch assembly, and packaging automation. Implemented automatic inspection equipment, Bluetooth wireless gage data collection, 4-shift operator model, and IATF 16949 certification.
Led process improvements across 5 manufacturing sites. Reduced lead time 50%, eliminated all customer rejects at fiber pedestal line, reduced unit cost 25% via Design for Manufacturing, and delivered $1.5M annualized savings through Hoshin-Kanri policy deployment.
Plant consolidation of three manufacturing businesses across CA, CO, and NJ. Delivered $20M per facility in cost reductions, $2.6M inventory reduction, doubled inventory turns, and 66% supplier DPM reduction at program inception.
Get Started
Every engagement begins with a no-cost preliminary assessment. We identify your highest-impact opportunities — quality, operations, or AI/technology — before any commitment is made.