Manufacturing Throughput Rebuild
Re-sequenced a stalled production line around the one number that mattered — cost per unit.
Illustrative figures, shown to demonstrate the format.
Illustrative case — structure and figures are a worked example. Replace with a real engagement, or delete.
The problem
A profitable manufacturer had quietly accepted a line that ran below its capacity for years. The business was healthy enough that nobody had to fix it — exactly the pattern potentiation exists to interrupt. Cost per unit had drifted up for six straight quarters, and no one could say precisely why.
The approach
We followed the number back to its source — a changeover process that had grown by accretion, never by design — and fixed the process before touching any technology.
- Mapped the changeover end to end and found the true bottleneck (not the one everyone assumed)
- Re-sequenced the process before adding any tooling
- Put scheduling automation behind the new sequence
- Brought in a controls specialist for the final 10%
The outcome
The line now runs to plan without the owner standing over it — and the numbers moved where it counts (see above). Most importantly, the gain is structural: it holds without heroics.
A number you'd like to move?
If something in your business should be working harder than it is, that's where we start.