Process improvement and predictive maintenance in one program
A short, focused review to find the opportunities, then an action plan that pairs line and process improvement with predictive maintenance. A dedicated team with operational excellence, industrial engineering, change management and predictive maintenance experience works with your people throughout.
2 weeks
Phase 1 opportunity review
4 to 6 weeks
Phase 2 action plan and implementation
Up to 90 days
Condition monitoring pilot, which can start during Phase 2
Phase 1 · 2 weeks
Opportunity identification
Data collection
We work with your personnel to gather production statistics, maintenance records, equipment information and process flowcharts.
Value stream mapping
Detailed maps of your key production lines to find bottlenecks, non-value-added activities and opportunities for improvement.
Line balance assessment
Line speeds, cycle times and staffing for each production stage, to find imbalances and use people and equipment better.
Change management planning
A plan that gets the improvements adopted and keeps disruption to ongoing operations low.
Phase 2 · 4 to 6 weeks
Action plan and implementation
Prioritization and recommendation first, then the work.
Line balancing recommendations
Line configuration changes for smoother flow and fewer bottlenecks.
Process improvement recommendations
Changes to production processes that remove non-value-added activities.
Predictive maintenance integration
Vibration and temperature sensors, oil analysis and other condition monitoring on the assets that matter most.
Training and knowledge transfer
Training for your personnel on the new solutions and on maintaining the gains.
Implementation support
Hands-on support while the recommended changes go in, and help with whatever comes up.
Governance
How initiatives move forward: IL0 to IL5
Every improvement passes the same gates, with named sign-off, so savings are counted only once they are real.
| Level | What it means | Requirements to pass the gate | Sign-off |
|---|---|---|---|
| IL0 Ideas | An improvement idea is logged | None | None |
| IL1 Idea generated | Measure described: initial situation, target state and approach | Measure lead identified, preliminary impact estimated, plan dates set for IL2 | Site manager |
| IL2 Assessed | Measure substantiated with a business case and approach | Key stakeholders involved, next steps and plan dates for IL3 to IL5 defined | Site controller |
| IL3 Approved | Detailed implementation plan with resources aligned | KPIs to track impact identified and projected, resources approved | Site manager |
| IL4 Implemented | Everything needed to create and sustain the value is done | Line management confirms the implementation | Sponsor, site manager, site controller |
| IL5 Financially realized | At least two months of impact recorded in the tracking tool | Controller approves the value, sustainability of the impact validated | Sponsor, site controller |
Deliverables
What lands on your desk
Value stream maps
Detailed maps for your key production lines.
Line balance analysis report
With improvement recommendations.
Action plan
Prioritized opportunities and how to implement them.
Training materials
Plus knowledge transfer sessions for your personnel.
Outcomes
What the program is built to improve
Production efficiency
Smoother production flow, fewer bottlenecks and better use of resources.
Unplanned downtime
Proactive maintenance that catches equipment failures before they stop the line.
Overall Equipment Effectiveness
Productivity and reliability gains from process and maintenance improvements together.
Decision making
Data you can act on for production planning and resource allocation.
Lasting operational excellence
A framework for continuous improvement that keeps the gains after we leave.
A continuous loop
The maintenance journey we set up with you
Goal setting, strategy, design and implementation, continuous improvement, then back to goal setting with better data each cycle.
- 1
Goal setting
- Customers
- Safety
- Compliance
- Risk
- 2
Strategy
- A maintenance plan per asset
- 3
Design and implement
- Resources needed
- Measurement and process feedback
- KPI tracking
- 4
Continuous improvement
- Review results, re-plan per asset, repeat
See where your lines lose time
The free assessment can include a first look at one production line before you commit to Phase 1.