Engagement 3 · Illustrative
Liberty Coach Production Diagnostic
Illustrative sample · numbers are simulated to illustrate the deliverable shape
What an AI-assisted diagnostic deliverable looks like for Kurt's side of the house. Margin leaks ranked, cycle time benchmarked by Edition family, tribal knowledge risk surfaced, and the next three moves laid out. Real engagement would build this on Liberty's actual production data, not these simulated figures.
Estimated annual recoverable margin
$0 K
Sum of the five ranked margin leaks below. The intent is to give Liberty a single number to anchor the conversation, not to claim certainty before the diagnostic runs against Liberty's actual data.
Top 5 margin leaks identified
- #1
Custom cabinetry rework cycles
Average of 1.4 rework cycles per coach on built-in cabinetry. Root-cause clusters in two specific module configurations and one supplier finish lot.
Annual recoverable
$0K
- #2
Long-lead Crestron component over-ordering
Buffer stock built against late 2022 supply uncertainty has not been right-sized. Approximately 11 percent of in-house Crestron inventory has aged beyond 14 months.
Annual recoverable
$0K
- #3
Stuart-to-Chicago in-progress coach relocations
Eight relocations in trailing twelve months tied to mid-build design changes. Each averaged 11 days of cycle-time impact and significant freight cost.
Annual recoverable
$0K
- #4
Artist Series exterior repaint touchups under warranty
Concentrated in coaches delivered Q3 2023 through Q1 2024. Specific clearcoat lot identified — recoverable via supplier conversation.
Annual recoverable
$0K
- #5
Optional-feature scope creep with no change-order capture
On 14 percent of trailing-year builds, post-contract feature additions were absorbed without formal repricing. Process gap, not pricing gap.
Annual recoverable
$0K
Production cycle time by Edition family
Days from order confirmation to coach delivery. Simulated benchmark — pulled from published delivery date patterns across recent Elegant Lady builds.
Tribal knowledge risk heatmap
| Role / knowledge area | Owner | Criticality | Bus factor |
|---|---|---|---|
| Crestron systems integration | A.K. | Critical | 1 |
| Production sequencing & module ordering | K.K. | Critical | 1 |
| Interior design library & fabric sourcing | Kim K. | Critical | 1 |
| Cabinetry shop CAD & jig setup | R.K. | High | 2 |
| Pre-delivery service inspection rubric | B.D. | High | 1 |
| Stuart mobile service dispatch logic | N.M. | Medium | 1 |
| Supplier relationship — Dean Loucks workflow | Frank Jr. | High | 1 |
| Long-lead purchasing — Prevost chassis windows | N.K. | Medium | 2 |
Recommended next steps
- 01
Stand up the cabinetry-rework feedback loop
Two-week sprint to instrument rework cycles by module, supplier lot, and finish. Targets margin leak #1 directly. Estimated $120K to $160K recoverable within one full build cycle.
- 02
Re-baseline Crestron buffer stock
Single-pass inventory walk and reorder-point reset. Targets margin leak #2. One week of effort, books $80K to $100K back into working capital.
- 03
Codify the change-order capture moment
A one-screen workflow that fires when a post-contract feature is added on the production floor. Closes margin leak #5 and surfaces real customization data for future pricing conversations.