Operations, engineering and leadership consulting since 2011
More capacity, less waste and stronger leaders for mid‑market companies.
We're not selling a service. We deliver a result: hard-cash savings that raise your EBITDA and enterprise value. Stefko Consulting helps owners and CEOs cut operating cost, capture M&A integration synergies, fix quality problems and develop their managers. You work directly with Joe Stefko, a Chemical Engineer and Lean Six Sigma Black Belt with 30 years running operations.
It costs nothing to talk to us or to get the analysis. You'll see exactly what your project is going to save before you commit.
- Chemical Engineer
- Lean Six Sigma Black Belt
- cGMP regulatory expert
- Former VP, US Operations
- John Maxwell leadership coach
Problems we solve
When pushing harder stops working
Mid-sized companies hit a point where the systems that held things together start to crack. These are the calls Joe gets.
Capacity has stalled
Equipment is maxed out and you are looking at a big capital spend. We remove bottlenecks and add capacity from the assets you already own.
Margins are getting squeezed
Material yield, downtime and supplier costs eat profit. We find the waste, cost it out and fix it.
Quality problems keep coming back
Rework, complaints and recalls. We get to the root cause and put corrective and preventive actions in place that stick.
You can't hire enough people
We train the team you have in Lean Six Sigma so they run leaner, and scope automation projects where they pay off.
An acquisition is not paying off yet
Post-acquisition overlap and confusion. We help with due diligence, integration and capturing the synergy savings.
Your managers are stretched thin
Managers wearing five hats. We coach them to lead through change, with you, not around you.
Services
What we do
M&A integration and synergies
- Operational due diligence before the deal
- Finding the synergy savings and integration projects
- Facility consolidation and moves
- Capturing the value before it leaks after the deal closes
Operational excellence and cost reduction
- Material yield and quality analysis
- OEE and uptime improvement
- Six Sigma process capability studies
- Design of experiments for cycle time and speed
Supply chain
- Alternate material sources and RFQs
- Cost optimization
- Supplier relationship management and specifications
- Product testing and results analysis
Product and process development
- Stage-gate product development
- Scale-up from R&D to manufacturing
- Process design, specifications and work instructions
Quality and compliance
- Corrective and preventive action (CAPA)
- Root cause analysis training
- Current Good Manufacturing Practice (cGMP)
- Process validation
Leadership coaching and training
- John Maxwell leadership coaching and masterminds for COOs and VPs of Operations
- DiSC assessments
- Lean Six Sigma Yellow, Green and Black Belt training
- Strategy and vision sessions
Revenue recovery and cost recovery programs
Hospital underpayment audits, plus expense reduction and cost recovery programs for employers, delivered with specialist partners.
How it works
Three steps, no PowerPoint shelfware
Free savings analysis
Tell Joe what is breaking: capacity, cost, quality, an acquisition or your team. It costs nothing to talk, and you'll see what the project is going to save you.
Find what's real
We look at your operation and your numbers, find the root causes and pick the top 3 projects worth doing first.
Implement and measure
We do the work with your team, measure the results and leave systems and people that keep running after we're gone.
How we pick what to fix
We don't try to fix everything at once. We find the top 3 projects, because those few usually drive about 80% of the profit, and we start there.
Proof
What leaders say about Joe
"Joe has made a tremendous impact since joining York a couple years ago... expanded the capacity of our facilities through process improvements, new technologies, and improved morale in the facilities."
"Joe is a go-to person that can be trusted to get the job done. He can analyze a situation and then articulate a clear plan of action."
"He came in at a very difficult period of change in the plant and turned the ship around."
"Joe was responsible for the transition of a newly acquired acquisition moving the entire operation to another state."
"I appreciate his enthusiasm and trust him to drive results including consolidation of facilities, growing the business and technical product transfers."
"I highly recommend Joe's expertise in operations, new product introduction, quality and safety improvement."
Where Joe has led operations, R&D and quality
- York Wallcoverings
- Adhesives Research
- Church & Dwight
- OpSec Security
- Miller Chemical and Fertilizer
About Joe
Built on 30 years in the trenches
Joe Stefko founded Stefko Consulting in September 2011, after decades running operations, leading R&D and fixing what was broken, from the production floor to the boardroom.
Before consulting, Joe served as Vice President of US Operations and as Director of Research and Development and Quality at manufacturing and converting companies. He understands the pressure, the budgets and the deadlines, and how to deliver under all three.
- Founder and President, Stefko Consulting LLC
- Chemical Engineer
- Lean Six Sigma Black Belt
- cGMP regulatory expert
- John Maxwell Leadership coach and mentor
- Offices in York, Pennsylvania and Punta Gorda, Florida
Let's talk about what's next
No flashy sales pitch. If you're staring down operational limits, book a free savings analysis and Joe will show you what's possible, what it will take and what it's going to save you.
Offices
York, PA 17402
Punta Gorda, FL 33983