Flagship visit
Throughput and downtime study
A multi-day presence on one production line to time units, name stop reasons, and separate planned changeovers from true lost hours.
Who it is for
Plant managers, production supervisors, and quality leads who already keep shift logs but cannot explain why a week’s planned units slipped.
What you leave with
A written line story: units per hour by shift, a ranked list of stop reasons with clock time attached, and a short set of floor changes the crew can try without a capital request.
Scope
One primary line, plus the immediate upstream buffer and downstream pack-off that starve or block it. We do not survey the whole plant in this engagement.
Included
- Opening walk with the supervisor to mark stations, buffers, and the official count point
- Timed observation across two full shifts and one changeover, with handwritten tally sheets later transcribed locally
- Stop-reason dictionary agreed with operators so “jam” and “waiting on parts” are not collapsed into one bucket
- Closing session at the line board to walk the ranked stops and the unit-per-hour run chart
Not included
- PLC or historian configuration
- Capital equipment selection
- Labor-relations bargaining
- Whole-plant OEE rollups
Who stands on the line
A Deploy Flowcore observer who stays on the floor, not a remote reviewer of exported files.
How the days run
Day 0 is a short call to confirm the line, count point, and shift pattern. Plant days cover observation, a mid-study check with the supervisor, and a close-out at the board. A written pack follows within five business days.
Duration
Three to five plant days on a single line, plus desk time for the written pack.
Where
On the shop floor at the client plant. The listed office in Alabaster is for correspondence only.
What the plant prepares
Open a visitor slot, name a supervisor host, provide the last two weeks of shift counts if they exist on paper or spreadsheet, and tell the crew why someone will be standing at the line with a watch.
Constraints
We work around lockout, food-contact rules, and union notification windows. Night shifts are included only when booked in advance. We do not override a supervisor’s stop-the-line call.
How it is priced
Quoted as a plant-day rate plus travel. See the rates page for starting figures and what changes the quote. Rates and quote factors.
Next step
Call or write with the plant city, the line name, and the shift pattern. There is no inquiry form on this site. Contact details.