A structured analysis of where time, labour and capacity are being lost across your operation. We identify and quantify the recoverable capacity sitting inside your current workforce before you consider adding headcount.
In a typical manufacturing or operations environment, between 30 and 50 percent of labour hours are consumed by activities that do not add value: waiting for materials, reworking defects, duplicating data entry, searching for information, attending unnecessary meetings, and managing workarounds for broken processes.
A productivity review makes this visible and quantifies it. Before you add headcount or invest in automation, understand exactly where your existing capacity is going.
Time spent waiting for materials, decisions, approvals, information, or the previous step to complete. Often the largest single category of non-value-adding time in manufacturing operations.
Time spent doing work again because it was not right the first time. Every hour of rework represents an hour of lost capacity and an underlying process or quality problem that needs to be addressed.
The same information entered into multiple systems, the same task performed by multiple people, or the same check done twice because nobody trusts the first check.
Time spent looking for tools, materials, information, or the right person. In manufacturing environments, poor layout and poor information management can consume several hours per shift.
Work done to a higher standard than the customer or the next step in the process requires. Precision where approximation is sufficient, documentation where a verbal update would do.
Capacity sitting idle because of poor production scheduling, unplanned downtime, or workflow imbalance between upstream and downstream steps.
We agree which part of the operation to review, establish how current productivity is being measured, and set the baseline against which any improvement will be compared.
We spend structured time in the operation, observing work as it happens, tracking time by activity category, and recording the frequency and duration of each waste type.
Every identified productivity loss is quantified in hours per week and translated into a cost. Opportunities are ranked by recoverable capacity so you can see clearly where the biggest gains are.
We produce a set of targeted recommendations to recover the identified capacity, with effort estimates for each and a sequenced improvement roadmap.
Tell us about your operation and we will tell you what a productivity review would involve.