From problem to proven.
A disciplined, four-phase method that finds the real constraint, builds the right fix, executes with your team, and makes sure the gains stick.
The #1 cause of missed performance.
Across independent industry studies, the pattern is consistent: unplanned downtime — driven by a reactive maintenance culture — is the single biggest cause of missed manufacturing performance. Our Reliability and Operations work is built to break that cycle.
Downtime is the #1 OEE killer
Unplanned downtime is the single largest OEE efficiency-loss category in manufacturing — bigger than speed or quality losses.
— Godlan OEE Benchmark Study, 2024 (n=1,470+ operations)
Outages every month
Over two-thirds of industrial businesses suffer unplanned outages at least monthly — at roughly $125,000 per hour ($4,000–$30,000/hr in food & beverage).
— ABB Value of Reliability Survey, 2023 (n=3,215)
Parts, not people
Nearly half of extended repair time traces to parts unavailability — not technician skill. MTTR stalls without spares tied to work orders.
— OxMaint MTBF/MTTR/OEE KPI Guide, 2026
Still run-to-failure
One in five plants still runs equipment to failure — the behavioral root cause of the downtime that drives missed OEE.
— ABB Value of Reliability Survey, 2023
Sources: Godlan OEE Benchmark Study (2024); ABB "Value of Reliability" Survey, Sapio Research (2023); Siemens "True Cost of Downtime" (2024); MaintainX State of Industrial Maintenance (2024–2025); Deloitte; SMRP best-practice benchmarks.
Four phases. No hand-waving.
Find the real constraint
We start on the floor, not in a conference room. We measure your plant's capacity and throughput, dig into the data, assess your team's structure and skills, and talk to the people doing the work. The goal: separate symptoms from root causes, quantify the gap between current and potential output, and pinpoint the highest-leverage opportunities.
Build the roadmap
We translate findings into a prioritized, resourced plan — tied to measurable outcomes and the standards you're accountable to. You'll know what we're doing, why, in what order, and how we'll measure success before any work begins.
Execute alongside your team
This is where most consulting stops and we're just getting started. We work shoulder-to-shoulder with your people — coaching, training, and building the muscle memory that turns a new system into how things are simply done here.
Verify results and hand off
We confirm the change held — with data, audits, and standard work that keeps it in place. Then we transfer full ownership to your team, so the improvement outlasts our engagement by years, not weeks.
Principles behind the process.
Go to the floor
Real answers live where the work happens. We spend our time where the product is made, not in slide decks.
Transfer the capability
We coach your team to own the system. Dependency isn't a business model we're interested in.
Measure everything
If we can't measure it, we can't prove it. Every engagement ties to concrete, trackable outcomes.
Clear from day one.
No mystery, no runaway scope. From the first conversation, you'll have a clear picture of the objective, the plan, and how we'll know it worked.
- A defined scopeClear objectives and boundaries before work starts.
- Regular check-insYou always know where things stand.
- Documented resultsEvidence of the change, not just a feeling that it's better.
Start with an assessment.
The best first step is almost always a clear-eyed look at where you are today. Let's schedule one.