Book a consultation
Recover Capacity

Loss Analysis.

There is a second plant inside your plant. Loss analysis finds it, prices it, and tells you what it is worth to take back. Book a Loss Analysis Conversation

It is the capacity you already own, already staff, and already pay for, but never ship.

Installed capacity 100%
Shipped output the plant you run
The second plant unpriced, unshipped
Loss Snapshot · Illustrative
48% of installed capacity never shipped
Breakdowns
High
Setup & adjustment
High
Reduced speed
Med

We run the analysis at the point where value is actually created, on the line itself.

Using our 30 Major Manufacturing Losses platform with focused emphasis on the 7 Big Losses, we measure where capacity is going, why it is going there, and what each loss costs you in throughput and contribution margin. That distinction matters. Most plants can list their problems. Very few can rank them by EBITDA.

The 7 Big Losses

Ranked by financial impact, not by whoever argued hardest in the meeting.

Illustrative ranking. Your plant's own order is set by the analysis, not assumed going in.

Relative loss weight Cumulative share · illustrative
80% of impact 100%
Breakdowns
Highest
Setup & adj.
Reduced speed
Defects & rework
Minor stoppages
Startup losses
Idling
Lowest
The output

A decision set,
not a report to shelve.

Every loss category carries a dollar figure, so leadership can sequence the work by financial return.

01
Priced
Every loss category valued in throughput and contribution margin.
02
Ranked
Sequenced by EBITDA return, not by opinion in the room.
03
Actionable
A sequenced work order leadership can execute, not a binder to shelve.
The result

Recovered capacity, without capital.

01
Lower cost to produce
02
More sellable volume off the same asset base
03
A measurable OEE gain
04
A floor under less daily stress

Unreliability is a margin tax. Loss analysis is how you find out what you have been paying.

Book a Loss Analysis Conversation