AI-Assisted Quality Engineering · Lean Six Sigma · Continuous Improvement
Closed Loop Consulting LLC helps manufacturers find what is really driving their defects, scrap, and audit risk, then close it out for good. Behind that work sit more than 30 years of hands-on experience in plants where a missed problem becomes a recall, not just a rework ticket.
What We Do
Closed Loop covers both sides of the problem: the quality engineering that proves a process is sound, and the operations discipline that makes the fix hold on the floor. Standards, measurement, and the statistics behind a capable process run through every engagement, from the first measurement to the final sign-off.
We design, build, and certify QMS that stand up to the toughest customer and regulatory standards in aerospace, automotive, and industrial manufacturing.
Real, lasting gains through DMAIC, Value Stream Mapping, and Kaizen events, run by certified Black Belts with a track record of multi-million dollar results.
Senior operations leadership in production, supply chain, and team design. The gains are measured in real cost and efficiency, and they hold long after we leave.
Good decisions start with good data. We build the dashboards, models, and trackers that turn raw process data into something your team can act on, and we build them on the platforms you already own.
Power BI dashboards, Minitab capability studies, SPC control systems: each one helps you see variation, catch a problem early, and prove the fix with numbers. We now lean on generative AI tools to get there faster.
Our Process
Every engagement runs through the same four phases, from finding the true root cause to confirming the fix still holds months later. Nothing is left open.
On-site gap review, process mapping, data collection, and a baseline measurement. We watch the line as it actually runs, not as the SOP says it should.
Root cause work using DMAIC, Fishbone, 5-Why, FMEA, SPC, GD&T review, and Minitab. Conclusions come from the data, not from assumptions.
We put the fix in place with your teams: control plans, standard work, digital tools, and the change management that makes operators own it. Built to last.
We measure again, confirm process capability, and check audit readiness. The loop is not closed until the numbers prove it, and the auditors agree.
Industries Served
Both principals have held senior roles inside the industries we serve. We know your standards, your customers, and your cost pressures because we have worked under 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 in North America, Latin America, Europe, China, Mexico, Brazil, and India, covering P&L, plant consolidation, and M&A integration.
The Principal
Closed Loop Consulting is led by a quality engineering specialist who has spent her career inside the same plants and functions she now advises, covering both the engineering discipline and the operations rigor a fix needs to hold.
Patrycja has spent more than 15 years in quality engineering across aerospace, automotive, and electronics. Her hands-on work covers QMS implementation, supplier development, Six Sigma projects, and process capability at scale. Her career spans Fortune 500 manufacturers in aerospace, automotive, and electronics, where she has supported quality and operations programs from the shop floor through executive review. She builds dashboards in Power BI, runs the statistics in Minitab and SPC, and uses GD&T and CMM knowledge to take precision clients from blueprint review through measurement sign-off. She also leans on generative AI tools to speed up documentation and analysis, which brings a modern edge to traditional engineering. She holds a B.S. in Industrial Management & Applied Engineering and an M.S. in Quality Engineering Management, both from SIU.
By the Numbers
A selection of results from the quality and operations programs behind Closed Loop Consulting. The same methods and discipline go into every client engagement.
Case Studies
A few representative engagements, spanning quality engineering, operations, and AI-assisted continuous improvement.
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.
Insights & Answers
Straight answers to the questions manufacturers actually ask us about audits, corrective action, certification, and the cost of getting it wrong. Written from experience, not theory.
Get Started
Every engagement starts with a no-cost assessment. We pinpoint where you stand to gain the most, whether that is on the quality side, the operations side, or in how you use technology, before you commit to anything.