Measure real variability
Direct observation at the workstation to map the gaps between operators and between sites.
Operational performance
Operational excellence starts by reducing deviations and operator-to-operator variability.
On the floor, no two operators ever perform the same task the same way. This variability generates deviations, erodes OEE and stretches cycle times. We reduce it by making execution reliable at the workstation, site by site, without depending on your key experts.
Measured impact
- −15 to −30%
- fewer deviations
- +2 to +5 pts
- OEE
- −15 to −30%
- cycle time
The real problem
Variability is the hidden cost of your performance.
You have the quality system, the SOPs and the KPIs. But real execution varies from one operator to the next and from one site to another — and that's where deviations, rejects and unplanned downtime are born.
< 30%
of processes are actually run consistently.
50%
variability possible between two operators on the same task.
5-15%
of revenue is lost to the cost of poor quality.
Our approach
Make the task reliable, not just the document.
We go down to the level of the critical task as it's actually performed at the workstation to close the gap between what's validated and what's mastered.
Define the useful standard
The right level of execution — neither over- nor under-documented — designed to actually be applied.
Transfer it to the workstation
Documentation and training focused on the critical task, so everyone performs the same way.
Close the loop on deviations
Detect and handle deviations faster to learn continuously and prevent recurrence.
Track the KPIs
OEE, cycle time, rejects and deviations managed over time, not merely observed.
Make your teams autonomous
We transfer the method: mastery stays with you, not with the consultancy.
Our results
What you gain.
The orders of magnitude observed once execution is made reliable.
- −15 to −30%
- fewer deviations
- +2 to +5 pts
- OEE
- −15 to −30%
- cycle time
- −5 to −15%
- rejects
Request an assessment.
Let's pinpoint together where your variability costs the most — and how much you can cut it. From €5k.