In a time when everything is changing all at once—on/off tariffs, federal funding and agencies disappearing with the stroke of a pen, increasing international conflicts, unpredictable weather, and rapidly changing technology—small manufacturing businesses can struggle to make decisions fast enough. They often implement inappropriate solutions, leaving them at a disadvantage in an increasingly competitive marketplace. Susan O. Schall, PhD, founder and lead consultant at SOS Consulting, LLC, has built her practice around helping small U.S. manufacturers establish strategic clarity and execute transformational improvements using a mix of organizational health and continuous quality improvement.
Dr. Schall works as an integrator, bringing together tools and concepts of process and statistical thinking to identify root cause(s) that, once resolved, give operations a competitive edge. Her work focuses on six essentials that build a cohesive leadership team that leads with clarity to focus on the critical few objectives that drive results so that everyone flourishes. She builds a basic foundation within the workforce before moving on to more sophisticated methodologies, such as Six Sigma and advanced quality management systems.
A Consultant’s Mindset
As lead consultant, Dr. Schall’s methodology is based on a mix of technical expertise and empathy. Her responsibilities include leading strategic clarity sessions with senior leaders, facilitating improvement projects, and training and coaching her clients in process improvement and change management methods. She often finds that her clients—leaders in sectors including chemicals, food, beverage, automotive, higher education and non-profits—must first undergo a personal change to guide their organizations through a broader transformation. Dr. Schall uses these same approaches to mentor young women pursuing careers in engineering.
The secret to Dr. Schall’s success, one that she often advises others, is to remain persistent: Define your purpose and goals clearly and be open to continuous improvement/learning.
A Smart Foundation
Dr. Schall’s expertise is supported by a strong academic background. She earned a Bachelor of Science in mathematics in 1981 from the State University of New York at Fredonia. She then completed bachelor’s, master’s, and doctoral degrees in industrial engineering from Pennsylvania State University in 1982, 1986, and 1988, respectively. Penn State later honored her with the Outstanding Engineering Alumna Award in 2009.
Beyond All Challenges
Dr. Schall’s dedication to her work extends beyond her consulting practice. She has held various leadership roles in her United Methodist Church. Susan has also served the Institute of Industrial and Systems Engineers (IISE) in various roles in ABET for 34 years. She was recognized as a Fellow of IISE in 2020. Additionally, she served as Treasurer of the International Statistical Engineering Association (ISEA) from 2023 to 2024 and is presently an At-Large Board member.
In her personal time, Dr. Schall’s hobbies include traveling and baking, which she says provide slower-paced learning compared to her technical work. She also recently served on several writing teams, completing two chapters of an industrial engineering handbook. Looking ahead, Dr. Schall aims to compile her over 200 blog posts into a book, titled “The Six Essentials of Healthy Manufacturing,” with the objective of equipping the next generation of small manufacturing leaders to create workplaces that compete today and tomorrow.
