Sample factoryIllustrative synthetic data. We built this from a real plant we assessed; we cannot share a client's private data, so this is a representative example of the analysis.

Pythia Industries
Sample dashboard

Factory map

The molding floor from above, resin to truck, with the regrind loop.

The presses set how much the plant can ship.

Click any zone to see what feeds it, what it feeds, and the fixes worth the most there.

Press OEE

~53%of scheduled press time makes good parts

The rest of the time is lost to changeovers, breakdowns, and slow cycles. The fixes on this floor raise it to about 68%, roughly 27% more good parts from the same 26 presses with no new machine. Freed press hours only add profit if sales fill them.

silosMATERIAL INshipping doorsRECEIVING & RESINdocks 1-3, bulk resinDRYERS & UTILITIEScentral conveyingMOLDING FLOOR~26 presses, by tonnageTOOL ROOMmolds, CNCOFFICES & ERPjob trackingSECONDARYassembly, pad-printQC LABmetrologySHIP OUTpack & shipoverhead craneIDLEdead pressesREGRINDgranulator12345
The material's pathThe selected zoneIdle presses & dead toolingParts waiting (WIP)Walled room (tool room, QC)

The selected zone

What feeds it, what it feeds, and what it is worth.

Fed by

The pressesStep 2 of 5

Molding floor

$467Kin improvements

Feeds

The problem

Every part runs through the presses, and they lose hours every day.

About 26 machines do all the molding, but they run on operator judgment rather than measured process settings, with slow changeovers, breakdowns, and cycle times padded past what the part needs. Recovering that time and steadying the process is capacity you already own, with no new press.

What it's worth

Total

$467K

Per year

$467K/yr

One-time

$0K

What to do

Put simple run tracking on every press, then go after the biggest loss first, whether that is changeover, downtime, or scrap.

Recover hidden press capacity$120KTake the padding out of the cycle$72KCut changeover time with SMED$54KCut scrap with scientific molding$120KPreventive maintenance on the presses$62KSwap to all-electric as presses retire$38K
The proof
  • Production counts live on a clipboard and a whiteboard, and nobody can state last week's uptime without digging
  • Cool timers are set with round-number padding to be safe and never trimmed with data
  • Operators walk back and forth for tools while the press sits dead during a mold change