Most manufacturers do not need new machines. They need the machines they have to report consistently, so that a line in one plant can be compared with a line in another.
How the programme runs
- Phase one instruments a single reference line and establishes the reporting standard
- Phase two extends the standard across the remaining lines at that site
- Phase three rolls the standard out to further sites, with local variation documented rather than absorbed
Each phase ends with a review and a decision point. Roughly a third of clients stop after phase two, having got what they needed from a single site.
What changes on the floor
Operators get a consistent line display that shows target against actual, current constraint and the reason for the last stop. Supervisors get shift comparisons that use the same definitions everywhere. Engineering gets changeover timings broken down by step, which is where most of the recoverable time is found.
Typical results
Across twelve completed programmes the median reduction in unplanned downtime twelve months after go-live was 18 per cent. The range was wide, from 4 to 31 per cent, and it correlated more with maintenance staffing than with anything we installed. We agree the baseline with you before work starts.