Performance Audit
See Where Your Real Capacity Is Hiding
Most lines lose 15-30% of capacity to invisible problems — micro-stops, speed loss, changeover drift. An ACI Performance Audit measures it on your line and hands you a prioritised plan to win it back.
Why it matters
The Losses That Hurt Most Are the Ones You Can’t See
Daily and weekly reports show averages. Averages smooth over exactly the events that drain output the two-minute stops nobody logs, the line running 8% under rated speed, the downtime booked to the wrong reason. An audit makes those losses concrete, on your equipment, with real numbers.
Measured, Not Estimated
We capture losses directly from the line instead of relying on memory, gut feel, or numbers entered after the shift.
Prioritised by Impact
You get the losses ranked by what they actually cost you so the first improvement you make is the one that pays back fastest.
A Plan You Can Act On
The audit ends with a concrete roadmap what to fix, in what order, and what it’s worth not a binder that gets shelved.
What happens
A Clear, Day-by-Day Process
No long consulting engagement and no disruption to production. We work alongside your team on one representative line, then translate what we find into a plan.
We See the Line as It Really Runs
A walk-through with your operators and supervisors to understand the process, the current reporting, and where the team already suspects time is being lost.
We Measure Real-Time on One Line
Output, speed, stops and downtime reasons are captured live typically with Vorne XL so we’re working from what the machine actually did, not a summary.
We Turn the Data Into a Loss Picture
A Pareto of your real losses: where the biggest hours go, which downtime is misclassified, how much sits in speed loss and changeovers.
We Sit Down With Your Team
A working session where we present the findings, agree the priorities, and lay out a practical improvement roadmap your team owns from day one.
What we typically uncover
The Four Losses an Audit Almost Always Finds
Scope
What’s Included and What Isn’t
We keep the audit deliberately tight: enough to give you a real, measured picture and a plan, without turning into a six-month project.
What you get
- Live measurement on one representative line
- A Pareto of your real losses, ranked by impact
- An estimate of the capacity that’s recoverable
- A prioritised improvement roadmap
- A findings session with your operators and management
What you won’t get
- A six-month consulting engagement
- Software you’re locked into to read the results
- A 200-page report nobody on the floor will read
- Generic benchmarks instead of your own line’s data
- Pressure to buy anything before you’ve seen the value
Questions
Before You Book
How long does the audit take?
Most audits run about a week from the first line-walk to the findings session, depending on your shift pattern and how many products run on the line we measure. We agree the exact timing with you up front.
Do we have to install software?
No. The audit measures your line and gives you the findings regardless of what you decide afterward. We usually capture data with Vorne XL, but you’re never locked into a tool to read or keep your results.
Will it disrupt production?
No. We measure the line as it runs normally the point is to see real production, not a staged demo. Your team keeps working; we work alongside them.
What do we actually walk away with?
A measured picture of where your capacity is going, the recoverable losses ranked by impact, and a practical roadmap your team can start on immediately agreed together in the findings session.
Is the audit tied to buying Vorne XL or OEE IntelliSuite?
No. The audit stands on its own. If the findings point toward real-time visibility or OEE IntelliSuite tools as the next step, we’ll show you why but that’s your call to make after you’ve seen the value.
Find Out What Your Line Is Really Capable Of
Book a Performance Audit and get a measured, prioritised view of your hidden capacity with no obligation to buy anything.
25+ years of shopfloor performance experience · Serving manufacturers across Europe