Free potential analysis · 30 minutes · Microsoft Teams
In the potential analysis we don't show any software. We go through where your production loses output today and turn those losses into euros, using your own figures.
You come away with a calculation you can defend internally.
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What we talk about
Most plants know exactly where things get stuck. What's missing is the number: what does it cost per year, and is it worth changing? That is what the potential analysis is about.
Faults are spotted late, and finding the cause depends on individual people. Every hour is missing from output and margin.
What does an hour of downtime cost you on your most critical machine, and how much of it is just searching and reacting?
Calculate your downtime costWhether an order or a shift is off plan only shows in the shift report. By then, all that helps is express freight, extra shifts and escalation.
What did express freight, extra shifts and escalations cost you last year?
Micro-stops and slow cycles stay invisible. Instead of getting capacity out of what you have, the talk turns to investment.
If you needed a tenth more output tomorrow: would you have to invest, or is the capacity already in your machines?
Calculate your OEEThe same changeover takes different times depending on the shift or team. Nobody has written down why.
What share of your planned time goes into setups and changeovers today?
Calculate your setup timeWhen a process drifts out of its window, often only the inspection notices. By then material, machine and people are tied up.
What do scrap and rework cost per year, and how much of it only shows up at the end?
Calculate your first pass yieldExcel, shift reports, local systems: the first half hour of the meeting goes into which number is right.
How many hours a week does your team spend collecting and reconciling numbers?
When the colleague who really knows the machine is away, every fault takes longer. What they know is recorded nowhere.
What happens during a critical fault when exactly that person is not there?
Every plant measures differently. Before you can compare, definitions and data have to be aligned by hand, and good solutions stay in one plant.
Can you compare two plants without reconciling data by hand first?
The calculation
Each loss is valued with a simple calculation you can follow and explain internally. You provide the starting values. If one is missing, we use a model value for your industry, and it stays marked as a model value. How much of a loss is avoidable is our cautious assumption, and it is marked as an assumption too.
A first number in advance? Calculate your downtime costNothing is counted twice. Capacity, OEE, setups and an avoided investment are different views of the same loss. They sit side by side in the calculation but are not added up. Only items that don't overlap are summed: downtime, scrap, expediting costs and alignment time.
What doing nothing costs. The sum of avoidable costs divided by twelve is what every month without change costs. That number gives you something concrete to discuss priorities with internally.
How the 30 minutes run
You don't need to bring anything. It only helps to roughly know what an hour of downtime or an express shipment costs you.
Choose a timeYour machines, lines and shifts. Which of these problems you recognise and how they show up in your plant, in your words.
For every problem you confirm, we record your number: hours, costs, frequency. If a number is missing, we use a model value and mark it.
What each loss costs per year, which of these costs can be added up, and what doing nothing costs per month.
How you would later measure whether something improved, and whether a next step is worth it. If not, we tell you.
What you walk away with
You receive the calculation as a PDF after the call.
To pass on
Anyone pushing for an improvement internally will sooner or later be asked what it delivers. These are the topics management looks at when it looks at production.
At Meleghy Automotive, downtime fell by 10% and output rose by 7%. Four plants were connected in six months.
Read the case studyIn the demo we show the platform on a real line. In the potential analysis we show no software; we calculate what your losses cost. Many do one first, then the other. See the demo
No. A rough idea of what an hour of downtime or an express shipment costs you helps. Where a number is missing, we use a model value and mark it.
Only where you are missing a number. Then a model value for your industry goes into the calculation, marked as such, and you see what share of the calculation rests on your own figures. The more values come from you, the more robust the result.
Whoever knows the losses from daily work: plant or production management, ideally with controlling or maintenance. Several participants are welcome.
They appear in the calculation you receive and are not passed on.
Nothing. The call is free and without obligation.
If a lever is worth it, we show you in the demo how SYMESTIC tackles it. After that, a proof of value is possible: 30 days on one of your machines, with success criteria agreed in writing beforehand. If nothing is worth it, we tell you.
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