Manufacturing Efficiency Consulting
Build a credible loss baseline for the process, product mix, schedule, and definitions your team actually uses.
A baseline needs context
Efficiency Starts With Clear Definitions
Availability, run performance, yield, flow, labor use, and schedule adherence answer different questions. Combining them without clear definitions can hide the loss that matters.
A focused review chooses the measure that connects to the production problem and makes its inputs visible to the people who act on it.
Time Loss
Separate planned stops, changeovers, missing work, breakdowns, waiting, and other causes.
Speed Loss
Compare actual behavior with a part-specific validated expectation.
Quality Loss
Track good output separately from scrap, rework, extra inspection, and repeat processing.
Flow Loss
Show waiting between operations so busy equipment is not mistaken for completed output.
Create a Practical Loss Ledger
- Choose one work center, product family, or shift.
- Agree on event definitions and start-stop rules.
- Collect enough observations to understand the largest category.
- Test the response and compare it with the baseline using the same definitions.
Manufacturing Efficiency Consulting Questions
Use a facility- and process-appropriate baseline. No universal CNC-shop or world-class percentage is asserted here.
That cannot be known before the current loss and usable countermeasure are understood.
Timing depends on the operating condition, data, access, and change being evaluated.
Start with the loss affecting the customer or schedule, then capture a practical baseline such as waiting, changeover, downtime, rework, queue time, or completed good parts. The right measure follows the production problem.