Your operational performance experts
At Metalstar Consulting, we are passionate about helping our customers achieve operational excellence to increase profit and ensure stability.
Moving the aluminum extrusion industry forward with 360-degree solutions
Metalstar Consulting is a manufacturing transformation firm serving the Aluminum Extrusion industry. We offer results-driven, people-focused solutions to billet suppliers, extrusion manufacturers, and extrusion users. Our team brings to the table a breadth and depth of industry expertise – from aluminum extrusion metallurgy and extrusion process auditing to engineering, to leadership coaching in the manufacturing context. Leveraging our onboard expertise and strategic industry partnerships, we’ve been able to deliver truly holistic solutions to clients across the US – from lab analysis, to die design, to leadership coaching.
Operations consulting
Operational excellence
Production excellence
Moving the aluminum extrusion industry forward with 360-degree solutions
Metalstar Consulting is a manufacturing transformation firm serving the Aluminum Extrusion industry. We offer results-driven, people-focused solutions to billet suppliers, extrusion manufacturers, and extrusion users. Our team brings to the table a breadth and depth of industry expertise – from aluminum extrusion metallurgy and extrusion process auditing to engineering, to leadership coaching in the manufacturing context. Leveraging our onboard expertise and strategic industry partnerships, we’ve been able to deliver truly holistic solutions to clients across the US – from lab analysis, to die design, to leadership coaching.
Operations consulting
Operational excellence
Production excellence
Sustained improvement equals big wins long term
Many manufacturing environments focus more on cost and quick wins.
We focus on optimizing your processes, standardizing oversight, and training your people to create sustained improvement over time.
Your team is your biggest asset
We believe human effectiveness is the secret to a successful organization. Your teams need the right placement, the right training and tools, and the right incentives to perform at their highest level. Every person is not the same. That’s why leadership must be intentional. We help you set the right tone to make every employee a part of your long-term success strategy.
Organizational alignment is the foundation of a successful operation
We believe intentional communication between leadership and workforce is essential to forging a successful path forward.
- Leaders must clearly communicate their organizational vision, goals, and expectations.
- Middle management needs to be involved in training and strategy.
- Coaching for both operators and management bridges the gap between strategic goals of the organization and people working to execute on those goals daily.
Customer experience management has never been more important
We believe that at the end of the day if you’re providing a great product and exceptional support to your customers, your organization will succeed. We help you create a strategy to streamline support when technical issues arise – whether it’s quality, capacity limitations, or other challenges.
Our Founder
Meet Johnny
Johnny has over 20 years of experience in applied aluminum extrusion metallurgy. His professional work includes leading various trainings, extrusion process auditing, department management, and process engineering.
Johnny has worked with industry leaders reducing scrap, increasing revenue and writing training procedures. His background as extrusion manager, process engineer, and quality manager at multiple sites provides a broad perspective on the aluminum industry.
Passion for People
First and foremost, Johnny has a passion for helping companies by helping PEOPLE become the best they can be. People make it happen, and no improvement activity will ever be effective without starting with people.
Encourage people to grow to be their best selves.
Education and Credentials
Certified Six Sigma Green Belt
Voting member of ASTM Subcommittee B07 and E01.04
Sample Past Projects
Major scrap reduction initiative – resulted in > 3M pounds saved annually
Productivity turnaround for struggling press line – stabilized and increased productivity 30% +
Key extrusion die design upgrades at multiple plants
Change culture to follow credible recipes for aluminum production
Extrusion process audit activities across the United States
Multiple 6xxx aluminum alloy implementations including press qualifications
Working with quality department to reduce scrap and defects (reduced 1.5%)
Cross tooled 10” and 8” press for operational flexibility, while improving die/container interface stability
Materials lab analysis of aluminum extrusion defects
In-depth training sessions for plant personnel and management focused on process control, quality, extrusion metallurgy, best practices
Publications
Pangborn, et al., “6005A: Practical evidence of advantages for extruders and their customers”, Proc. of the 10th Intl. Alum. Extrsn. Techn. Sem., 2012 (Presented May 2012)
Pangborn, et al., “Simple temperature measurement techniques for extruders: Straightforward solutions in a tough market”, Proc. of the 10th Intl. Alum. Extrsn. Techn. Sem., 2012 (Presented May 2012)
Personal
Years of Experience
Projects Completed
Professional Certifications
Publications
Contact Us
(715)680-8409
contact@metalstarconsulting.com
Office Hours
Mon-Fri: 9am - 5pm
Sat-Sun: Closed