Find Where Your Production Capacity Is Being Lost
In 1–2 days, ACI identifies the losses that matter most: downtime, speed losses, changeovers, bottlenecks and other constraints limiting output.
A focused review of what is really limiting performance, and what to do about it. Start with facts, priorities and practical actions.
Where is performance being lost?
We look beyond the headline OEE number to identify the specific losses that shape your daily output. The ones your team feels but the reports rarely explain.
Downtime
Recurring stops and their real causes. Not just the reason code, but the pattern behind it.
Speed losses
Running below achievable rate. Hidden micro-slowdowns that add up across every shift.
Small stops
Frequent brief losses that often disappear in reporting but eat real capacity.
Changeovers
Preparation, waiting and start-up losses that compress the productive time in every run.
Bottlenecks
Where flow and capacity are constrained. The machine, station or step that caps the line.
Quality losses
Rejects, rework and unstable processes that consume capacity you already paid for.
Organisation & working methods
Planning, standards, communication and daily management. The human side of production.
A clear picture, and a prioritised path forward
You leave the audit with facts you can act on the same week, and a roadmap that gives management and the production team the same starting point.
A clear picture of current production performance
The main sources of lost capacity
Downtime, speed and changeover losses that deserve attention
The key bottlenecks and constraints
Quick wins that can be addressed immediately
A prioritised improvement roadmap
Clear next steps for management and the production team
A focused, four-step review
Practical, evidence-based, and grounded in what actually happens on your floor. Not a generic checklist.
Shopfloor observation
We observe the process where the work happens. Machines, operators, flow, stops and changeovers.
Data & loss analysis
We review the available production, OEE, downtime and process data and compare it with what we see on the floor.
Team discussion
We involve operators, supervisors and management to understand what sits behind the numbers.
Priorities & actions
You receive a concise summary of the main losses, quick wins and recommended next steps.
Where does your OEE actually go?
Every plant has a version of this waterfall. Availability, performance and quality losses stacked against theoretical output. The audit turns your version from guesswork into evidence.
You see the losses you can fix this month, the ones worth a project, and the ones that need continuous measurement to stay solved.
When Is a Performance Audit Useful?
A performance audit is particularly useful when:
- OEE is below expectation but the reasons are unclear
- Production output is inconsistent
- Downtime figures do not match what people see on the floor
- Lines run below target speed
- Changeovers vary significantly
- Teams collect plenty of data but struggle to turn it into action
- Management suspects hidden capacity is available
- You are considering an OEE or production-monitoring solution and want to know where to start
The Audit Is the Starting Point, Not the End Product
Depending on what we find, the next step may be:
Practical manufacturing experience
Ready to see where your capacity is going?
Book a performance audit and get the facts, priorities and practical next steps within 1–2 days.