One program. Six months. Gains that hold.
Maintenance and production on the same plant goals, the same scorecard and the same daily meeting, measured against your own numbers.
The FORGE OS Plant Alignment Program.
Six months. The first 90 days put maintenance and operations on the same plant goals, the same scorecard and the same daily meeting. The next 90 make it hold, with or without me in the room. We measure both.
Fault Lines
Floor walks on both sides. Interviews from the ops manager to the operators. KPI baseline.
Validated cost of the gap
Ownership
Leaders set the plant goals. Each side commits to what it will do and what it needs from the other.
Signed Alignment Charter, one joint scorecard
Rigor
PM release paired with planned, kitted jobs. Operator basic care paired with technician cause reporting.
Habits in place. First results reviewed at day 90.
Gain
Joint root cause on repeat failures and startup losses. Close the biggest losses. Coach supervisors through the hard months.
Measured improvement on your numbers
Elevation
I step back and the plant runs it. Final measurement and a results review with your GM and CFO.
A results report and a plan to sustain it
The plant leader is my partner.
I don't do this to a plant. I do it with its leader.
- Opens the kickoff and tells the plant it has full backing
- Sets two or three plant goals and signs the Alignment Charter
- Regular check-ins with me, clearing what's blocked
- Leads the day-90 and final results reviews with me and the CFO
How results are measured
- Baseline from your systems.Month 1. Downtime, OEE, overtime and scrap pulled from your own records, not my estimates.
- Targets in writing.Each plant goal in the Alignment Charter carries a number. Example: Line 2 downtime from 6 hours a week to 3 by day 90.
- Tracked weekly.One joint scorecard, reviewed every week against the baseline.
- Reviewed at day 90, signed off at month 6.Results reviews with your GM and CFO. Cost per unit and payback, in their terms.
A plan, not a promise. The Diagnostic and the Alignment Charter give you a target. Your teams turn it into savings. I plan with you, teach, and course-correct, but the results come from engaged, aligned people on your floor doing the work. That is also why they last.
The cost · Illustration
Now picture the gap in your plant.
Brakebush was one line. Here is how the same gap usually adds up across a whole plant. The question isn't what outside help costs. It's what the gap costs every week you leave it open.
| Example plant: where it shows up | Per week | Per year |
|---|---|---|
| PM windows not released, so the line breaks down instead5 hrs/wk unplanned downtime × $2,500/hr | $12,500 | $625,000 |
| Scrap and rework after breakdowns, startups and changeovers$40M production × 3% scrap × 1/3 tied to equipment | $8,000 | $400,000 |
| Overtime spent chasing the schedule80 unplanned OT hrs/wk × $32 × 1.5 | $3,840 | $192,000 |
| Turnover under untrained supervisors150 people × 40% turnover × $5,000 to replace | $6,000 | $300,000 |
| Total gap | $30,340 | $1.52M |
Added to every unit shipped
A year back if you recover a quarter of the gap
What one hour down on the bottleneck costs
Illustration only. Example plant: 150 people, $40M a year, 4 million units, 50 weeks. Turnover is priced at a conservative $5,000 per person.
See where your plant standsWhere I work
A small number of plants at a time.
I take on a small number of plants at a time, so each one gets my full attention. These are the industries I've worked in.
- Food, beverage and ag processing
- Pulp, paper and packaging
- Chemical and petrochemical
- Mining, metals and fabrication
- Equipment
- Aerospace and defense
- Consumer goods
- The gap between maintenance and production looks the same in every plant.
First step
Every conversation has one clear next step.
Plant Alignment Check
Four questions, two minutes. See how aligned your two sides are.
Walkthrough call
Thirty minutes. You tell me what's happening on your floor. We review your Alignment Check answers together. I tell you whether it's worth a closer look, and where I'd start.
Plant Gap Diagnostic
Two days on site watching both sides. Within a week: a written map of the gap, what it costs, and the first three fixes. It counts toward the program if you go on.
Six-Month Alignment Program
90 days to install FORGE OS, 90 days to make it hold. Measured against your baseline.
Sustain partnership
Monthly support after month six. Expand to other lines or plants.
Start with the Plant Gap Diagnostic.
Two days on site watching both sides. Within a week you get a written map of the gap, what it costs, and the first three fixes. It starts with a 30-minute call.