Kamil Dyczkowski | Operational Process Diagnosis for Manufacturing & Warehousing

The Process Architect

I help business owners regain control when operations stop scaling with revenue.

Most operations run on experience, memory, and good intentions. That works until scale, pressure, or change expose how fragile that model really is. In high-stakes manufacturing and warehouse environments, margins are rarely lost through single failures – they erode quietly through process friction and decisions made where structure should exist.

I diagnose where operational control is leaking: where decisions are made without clear rules, where signals are ambiguous, and where ownership is implied rather than defined. I then rebuild the process so outcomes depend on explicit logic and clean signals, not interpretation or heroics.

Decisions are made once, correctly, and for the right reason - regardless of who is on shift. Over the past 20 years, I have worked across the full operational chain – from NPI programs through production to high-volume e-commerce. Based in Yorkshire, I work with clients locally and across the UK where instability is expensive and guesswork is unacceptable.

The result is an operation that behaves predictably under load, produces data you can trust, and no longer relies on informal workarounds to function.

The tools are secondary. Control is the product.

What Leaders Say

“The validation layer removed rework from our inbound flow. Errors were blocked at source, not corrected weeks later.”

Head of Logistics - UK operation

“Clear diagnosis, clear execution. The process stopped relying on individual judgement and became predictable.”

Site Manager - Yorkshire Food & Beverage

“Operational reporting became trustworthy. We reduced manual admin time and improved auditability.”

Operations Lead - Warehouse

Quotes are anonymised to respect confidentiality agreements.

Operational Friction

Do you recognize these symptoms in your business?

In every case below, the root cause is the same: decisions made where rules should exist.

Process Inefficiency

You are hiring more people, but output remains flat. You are scaling chaos instead of scaling the business.

High error rates requiring constant correction.
Teams engaged in manual, low-value repetition.
Confusion over roles and process ownership.
"Firefighting" mode becomes the daily standard.

Information Silos

Management decisions are made on "gut feeling" or outdated reports, not real-time facts.

Your WMS/ERP data contradicts physical stock.
Critical info trapped in emails or Excel sheets.
Lack of visibility on true operational costs.
Departments working in isolation, not synchronization.

Digital Disconnect

The gap between "how you work" and "how your tools work" is where you lose money.

Using expensive software that doesn't fit the workflow.
Reliance on "Shadow IT" (rogue spreadsheets).
No automation for simple, repetitive data entry.
Processes built around tool limitations, not business needs.

Case Study: Eliminating Human Judgement from Goods-InFirstStep - Food & Beverage

This project removed manual decision-making from a critical Goods-In step. The system enforces validation logic automatically - operators no longer decide whether a delivery is correct. The process does.

Goods-In Errors

97%

from 30-50% input errors

Inbound Processing Time

60%

reduction vs baseline

Operational Capacity

>2,000h

annualised conservative estimate

Desktop UI Preview

Live Deployment: Food & Beverage Sector

Automated Goods-In Validation

A bespoke application integrating directly with the ERP. It removes judgement from the operator - deterministic validation decides if the delivery is correct, not the human.

Mobile UI Preview

Mobile WMS Module

Logic: Real-time Feedback

Validation Logic UI

Old Way

Human decides

Interpretation at the point of entry
Inconsistent data quality
Errors discovered days or weeks later

Decision -> Cost

Deterministic Layer

Rules validate

Validation rules enforced at entry
Invalid data blocked by default
Clean data - fewer corrections

The "Before" Scenario

The original Goods-In process was heavily reliant on manual data entry. With an average of 10 deliveries per day, the system was fragile.

High Failure Rate: 30-50% of all deliveries contained data entry errors requiring retrospective correction.
Time Sink: Processing a single delivery took 60-90 minutes, often creating backlogs on the shop floor.
Correction Cost: Significant management time was wasted investigating and fixing "silent" errors weeks after delivery.

The Solution Impact

I implemented a bespoke VBA/SQL validation layer that acts as a firewall between the operator and the WMS.

Drastic Speed Increase: Validation time dropped to 20-30 minutes per delivery.
Error Elimination: The algorithm enforces logic (BBE, Shelf Life, Batch Uniqueness) preventing invalid data from ever entering the system.
Resource ROI: Calculating conservatively (50min saved per delivery × 10 deliveries × 250 days), we recaptured over 2,000 operational hours annually.

Key Outcome

Human judgement was removed from the most error-prone step of the inbound process.

Engagement

One entry point. Clear scope. Diagnosis first - implementation only if needed.

Operational Diagnosis

I examine how work actually flows, where decisions create cost, and why the data becomes unreliable. You receive a practical blueprint to regain control: what to enforce, remove, redesign, or instrument - with a clear ROI hypothesis.

On-site (Yorkshire) or remote discovery
Decision points map
Root-cause findings (not symptoms)
Blueprint + implementation options

Implementation (Optional)

If the diagnosis shows a structural gap, I can lead the stabilisation: process redesign, SOP + ownership, and - where required - industrial-grade validation layers that block errors at entry. Tools are an outcome, not a starting assumption.

Process layout + sequence redesign
Clear SOPs + ownership model
Proactive signals & controls
Validation systems when required

Audit-to-Implementation

My engagement model is modular. I don't lock you into open-ended contracts. We proceed step-by-step, and you retain full control over the decision to move to the next phase. Here is exactly what happens when we work together.

Phase 01

Operational Blueprint (Audit)

We start with an initial consultation to define the friction points. I don't rely on assumptions.

I conduct a thorough audit of key processes (on-site in Yorkshire or remote) and interview your staff.

Finally, I analyse the observation results to isolate the root cause, not just the symptoms.

Phase 02

Deterministic Design

I prepare a comprehensive solution design. We discuss the roadmap, the tools needed, and the expected ROI.

The Choice Point:
At this stage, you have a complete blueprint. You can implement internally, but most clients keep me involved to de-risk execution and stabilise the new process.

Phase 03

Implementation & Stabilisation

If you choose to proceed, I take full ownership of the deployment.

I build the tools, reconfigure the workflow, and train your team. I remain hands-on until the new process is stable and delivering the projected results.

No theoretical advice - just a working system delivered to your business.