Running, but leaving money on the table.
Not every plant is in crisis — some just quietly run below what they're capable of. Soft OEE, margin erosion, creeping downtime, quality drift. We diagnose the real constraints across operations, reliability, quality, food safety, and SQF, then hand you a prioritized, quantified roadmap to close the gap between how the plant runs and how it should.
Typical timeline
Most diagnostics run a few days to a few weeks depending on plant size and scope — fast enough to act on, thorough enough to trust.
An honest baseline — before you invest.
You can't fix what you can't see. Before committing capital, headcount, or a full engagement, an operational assessment gives you an outside, experienced perspective on what's actually driving — and limiting — plant performance.
- Objective current-state baselineAn unbiased read of the plant as it runs today — the numbers, the floor, and the systems behind both.
- Root-cause gap analysisWe separate symptoms from causes and identify the constraints truly holding back throughput, cost, and compliance.
- Quick wins & quantified upsideWhat can be captured in weeks versus what needs investment — sized so you know where the return is.
- Prioritized action roadmapA sequenced plan — what to fix first, second, and third — with owners, effort, and expected impact.
Every system that touches performance.
The diagnostic looks across the full operation — not just one department — because the biggest losses usually live in the seams between them.
Operations & throughput
OEE, line balance, changeovers, scheduling, labor, and the constraints capping output.
Maintenance & reliability
Downtime drivers, PM discipline, spare parts, and reactive-versus-planned maintenance mix.
Quality & food safety
Complaint and hold trends, HACCP/preventive controls, sanitation, and systemic quality risk.
SQF & audit readiness
Certification gaps, documentation health, and exposure ahead of a GFSI or customer audit.
Cost & yield
Material and labor variance, giveaway, scrap and waste, and the levers behind unit cost.
People & systems
Org structure, roles, standard work, training, and the data and KPIs the plant runs on.
A diagnostic is the smart first step when…
You suspect upside
The plant runs, but you're convinced there's meaningful margin, output, or cost left on the table.
You're weighing a deal
Pre- or post-acquisition, you need an independent read on operational risk and value-creation potential.
You need a plan you can trust
Competing priorities and opinions internally — you want an objective, sequenced roadmap to align around.
An assessment often becomes the front end of a larger engagement — but it stands alone, and the roadmap is yours to run with, in-house or with us.
Start with clarity.
A few days on-site can change how you see your plant. Let's scope a diagnostic that fits your operation.