About Star Consulting

Star Consulting Group is an international advisory firm dedicated to improving the performance, quality, and profitability of diesel engine remanufacturing operations. We support organizations across the mining, construction, energy, marine, and heavy industrial sectors by helping them strengthen the systems, processes, and workflows that drive effective remanufacturing programs.

Our consultants bring more than a century of combined experience across OEM engineering, global remanufacturing, production systems, and large-fleet maintenance. Their backgrounds include senior engineering roles at leading engine manufacturers, executive leadership within remanufacturing organizations, and decades of technical field experience in some of the world’s most demanding industrial environments. This expertise enables us to assist clients at every stage of operational development—from designing efficient process structures to implementing standardized, data-driven workflows on the production floor.

Star Consulting Group’s advisory work is founded on three core principles:

Technical depth, built on decades of engine design, calibration, and product development;

Operational insight, gained from managing remanufacturing plants, machining programs, and production teams; and

Systems optimization, focused on improving productivity, consistency, and decision-making through reliable process controls and performance data.

Our consultants have contributed to major advancements in remanufacturing practices, salvage processes, and large-equipment reliability programs, and our recommended methods are in use across the global diesel industry. As we expand our presence throughout Europe, Central Asia, Japan, and other international markets, we remain committed to delivering solutions that adapt to regional requirements while maintaining consistent global standards.

Whether clients are developing a new remanufacturing operation, evaluating workflow efficiency, upgrading machining processes, or seeking to enhance the reliability of large industrial fleets, Star Consulting Group provides clear guidance and measurable improvements that support long-term operational success.

David Bianchi

David Bianchi has more than 30 years of experience in the diesel engine remanufacturing industry, with a career spanning machining operations, production leadership, and executive management. He began in 1993 setting up machine shops and operating equipment across a wide range of industrial environments. Over the years, he has worked extensively with customers around the world, building a strong international network within the remanufacturing community.

David is known for aligning teams, processes, and customer relationships to achieve measurable operational improvement. His leadership roles have included serving as President of H-E B&G Machine Inc., where he implemented efficiency initiatives that strengthened the engine rebuild program and significantly increased profitability. As Vice President of Sales, he guided his team into new geographic regions and markets, contributing to a tenfold increase in revenue over 15 years.

An active contributor to the industry, David served as Chairman of the Board for the Automotive Engine Rebuilders Association and continues to serve on its advisory committee. His experience in organizational development, process improvement, and business growth supports clients seeking to modernize and expand their remanufacturing capabilities.

Brent Boutilier

Brent Boutilier brings 35 years of experience from the mining and heavy-equipment industries, with a career rooted in the demanding oilsands environment of Fort McMurray, Alberta. Beginning as a Heavy Duty Mechanic, he worked for 15 years in shop and field roles before advancing into planning, operations, maintenance, and reliability leadership positions.

Brent’s expertise covers large-scale mobile equipment fleets from major manufacturers, including Caterpillar, Komatsu, Liebherr, and Hitachi. He has a proven record in failure analysis, maintenance strategy development, and improving equipment availability in conditions that place extraordinary demands on machinery. His work in the oilsands—one of the world’s most rigorous testing grounds for heavy equipment—has given him a deep understanding of long-term fleet reliability and operational risk reduction.

As the founder of METS-MRS (Mine Equipment Technical Services – Maintenance/Reliability Support), Brent has helped organizations strengthen safety performance, productivity, and equipment life-cycle management. His experience supports clients seeking to optimize fleet strategies, enhance maintenance programs, and improve the reliability of high-value assets.

Johnny Bianchi

Johnny Bianchi specializes in developing and optimizing remanufacturing systems for industrial diesel engines and components. His career has focused on designing production processes, establishing operational controls, and creating standardized workflows that improve quality, efficiency, and consistency on the shop floor. His systems-based approach ensures that remanufacturing operations produce reliable, repeatable results supported by accurate production data.

Johnny has played key roles in building remanufacturing programs and identifying emerging market opportunities. His ability to recognize shifts in the aftermarket, combined with his technical background, has allowed him to guide organizations toward sustainable growth and improved engine life-cycle performance. His experience spans both hands-on shop floor management and executive-level decision-making.

With a focus on aligning people, assets, and systems, Johnny supports clients in developing structured remanufacturing operations that deliver strong long-term results. His work emphasizes continuous improvement and disciplined process control, helping organizations build operations that are resilient, scalable, and economically sound.

Douglas Free

Doug Free brings 38 years of engineering experience from Cummins, where he served as a senior technical product engineer responsible for a broad range of diesel engine development and optimization activities. His work included performance analysis, fuel system calibration, turbocharger selection, cam profile development, new product introduction, warranty problem resolution, and refinement of remanufacturing salvage processes.

Throughout his career, Doug led design teams across numerous high-impact engine programs, including NT444, N14, ISX, ISM, ISV, QSK60, QSK78, and QSK96. This deep involvement in engine design and development provides him with a comprehensive understanding of how engines can be effectively remanufactured and supported throughout their service life.

Doug also spent four years in Cummins Recon improving replacement factors for remanufactured products, and he has continued consulting on high-horsepower remanufacturing projects following his retirement. A licensed Professional Engineer with a degree in Systems Engineering, he holds more than 20 patents. His technical expertise supports clients seeking to strengthen the engineering foundation of their remanufacturing operations.