re: So talk to me about being a consultant in my spare time...

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Most of my friends who are business owners and/or middle managers with direct reports have already mined me for free advice or consultation

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Well I think it's time you ask that they repay the favor by reaching out to their network and seeing if they get your some leads.

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There's a ton of efficiency to be gained by taking a meticulous approach to policy and process

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Absolutely agree. This is the type of consulting practice I work in... but its not always easy to tie efficiencies gained to $$.

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2-200 people

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That may be a problem. Those types of companies usually don't have a lot of extra capital on hand to invest in process improvement projects. If its something you can come in, charge a 1-time fee, and show results quickly then it may be feasible for small companies.