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Manufacturing Operations Consultancy

Unreliability is a margin tax.

We find what your losses cost in EBITDA, price them line by line, and take them off the books. No capital request required.

See what your losses cost Talk to us →
Where best practices take hold.
On site · Reliability assessment
Where best practices take hold.
$8M
Margin gain on a single line, with no new capital spent.
The Little Potato Company, Bosch line
$1M
Manufacturing variance savings in year one, on pace to repeat.
Riverside plant, Wisconsin
40% to 65%
OEE recovered on a plant that had lost control of it.
Momence plant
01 · The Problem

You are quoting capital for capacity you already own.

Most plants run well below the rate they were designed to hit, and after a few years everyone stops calling that a problem. It becomes the number you plan around.

It is not the number you are stuck with. There is a second plant sitting inside the one you already built, and it shows up on your P&L as margin that was never captured. Every hour lost to unplanned downtime, slow running, extended changeover, and scrap carries a contribution margin figure attached to it. Nobody adds them up, so nobody defends them.

We add them up. Then we go get them.

02

Every loss carries a dollar figure. We find it, price it, and rank it by what it returns.

A full line loss analysis built on our 30 Major Manufacturing Loss platform, with focus on the 7 Big Losses. You leave with financial outputs, not a maturity score.

01
Cost, Volume, Profit Analysis
What each point of recovered capacity is worth at your current cost structure and price point.
02
Throughput Opportunity Pareto
Where your recoverable capacity actually sits, ranked largest first, measured at the constraint rather than averaged across the plant.
03
Sales Revenue Pareto
The revenue those recovered hours convert into, so the number survives the walk from the plant floor to the finance meeting.
04
Prioritized Roadmap
Each opportunity ranked by financial value, risk reduction, and how hard it is to execute. You get a sequence, not a list.
Cost / Volume / Profit chart
Throughput Opportunity Pareto chart
Schedule a loss analysis
03

What this looks like when it is finished.

Restoring Control and Performance at the Momence Plant
ReliabilityX Blog
Restoring Control and Performance at the Momence Plant
Riverside Plant Reclaims Control and Cuts Costs with ReliabilityX
ReliabilityX Blog
Riverside Plant Reclaims Control and Cuts Costs with ReliabilityX
ReliabilityX Unlocks Throughput and Cost Savings for The Little Potato Company
ReliabilityX Blog
ReliabilityX Unlocks Throughput and Cost Savings for The Little Potato Company
ReliabilityX Delivers $8M Margin Gain on Bosch Line for The Little Potato Company
ReliabilityX Blog
ReliabilityX Delivers $8M Margin Gain on Bosch Line for The Little Potato Company
ReliabilityX Breaks Throughput Records on Rotary Line
ReliabilityX Blog
ReliabilityX Breaks Throughput Records on Rotary Line
Read the full results →
04

Four steps, a defined end, and a team that does not need us afterward.

01
Quantify
We measure where capacity is being lost and what each loss is worth. You get the number before you commit to fixing anything.
02
Prioritize
We sequence the work by return, not by what is easiest to talk about. Early wins fund the rest of the program and buy you organizational support.
03
Implement
We work alongside your team at the point where value is created. We set standards, build the daily routines that hold them, and audit against the process.
04
Hand off
Your people run it. We train them to solve the next problem without us, because a result that depends on a consultant is not a result.

Industries We Serve

Equipment and process constraints differ by sector. The way losses hide inside a P&L does not.

  • Food and Beverage
  • Wood, Lumber & Panel
  • Pharmaceutical & Life Sciences
  • Chemical & Process Mfg.
  • Power Generation & Utilities
  • Consumer Packaged Goods
  • Automotive & Heavy Equipment
If your operation is not on this list, the question worth asking is not whether we know your equipment. It is whether your losses have ever been priced.
06 / Who We Are

Practitioners, not presenters.

ReliabilityX was built by people who ran plants before they advised them. We are the only consultancy with two CMRP of the Year award winners on staff. Our team holds CMRP, CRL, and CRLBB credentials, writes for Plant Services Magazine, and speaks at the industry conferences where this work gets argued about.

When we tell you a loss is worth seven figures, we have stood on the line where it happens.

Meet the team →
Practitioners, not presenters.

Where do you want to start?

I need the number.

Run the diagnostic and find out what your losses are costing you this year.

Start the assessment
I need my team trained.

Courses, playbooks, and certification paths for maintenance and operations teams.

See training
Client Outcomes
During a large complicated EAM upgrade project we were struggling with development of a training program and approach. At the same time, we were working to align our organization on Maintenance and Reliability Best Practices. Through a colleague, I learned about ReliabilityX, reached out to them to see if they could help and quickly learned they had the knowledge & experience to assist. I was amazed at how quickly they understood our struggles and could offer solutions. When it comes to Asset Management and Maintenance, Operations and Reliability they just get it. So glad to have them on my Team!!
Jason Herman
EAM-Change Management & Training Lead - Evergy

Tell us where you're stuck.

We'll bring a clear, sequenced plan to get your operation moving — and a number before you commit to anything.

Talk to us