Tool Bundles
Every system profile has a matched set of tools, sequenced across three phases. The right tools, applied in the right order, make the difference between improvement that sticks and effort that fades.
Correct sequencing matters. Tools are selected, not dumped. Each phase builds on the previous.
Firefighting Factory
Stabilise & See
Stop the chaos
- Visibility
Visual Management Boards
Make problems visible as they happen
- Stability
Escalation Protocols
Structured response to problems
- Stability
Daily Accountability Meetings
15-minute problem surfacing
- Visibility
Basic OEE Tracking
Understand where time goes
Fix the System
Address root causes
- Quality
5 Whys Analysis
Find root causes, not symptoms
- Stability
Preventive Maintenance Schedule
Stop breakdowns before they happen
- Flow
Standard Work Definition
Document what good looks like
- Quality
Problem-Solving A3s
Structured improvement method
Lock In & Scale
Sustain the gains
- Automation
Automated Alerts
Proactive notification systems
- Automation
Integrated Maintenance System
Predictive maintenance capability
- Visibility
Real-Time Performance Dashboards
Instant operational awareness
People-Dependent Factory
Stabilise & See
Capture the knowledge
- Visibility
Knowledge Mapping
Identify what lives in people's heads
- Planning
Skills Matrix
Map capability gaps
- Stability
Process Documentation
Write down what experts do
- Stability
Shadow Training Program
Structured knowledge transfer
Fix the System
Build systematic capability
- Flow
Standard Operating Procedures
Repeatable process guides
- Quality
Training Certification Program
Verified skill development
- Planning
Decision Trees
Codified decision logic
- Stability
Cross-Training Matrix
Reduce single points of failure
Lock In & Scale
Embed in systems
- Automation
Digital Work Instructions
Interactive, accessible guidance
- Automation
Knowledge Base System
Searchable expertise library
- Visibility
Competency Tracking System
Automated skill management
Data-Blind Factory
Stabilise & See
Create visibility
- Visibility
Manual Data Collection Forms
Start measuring basics
- Visibility
Hourly Performance Boards
Real-time manual tracking
- Stability
Downtime Logging
Capture what stops production
- Visibility
Output Counting Systems
Know what you're producing
Fix the System
Connect data to action
- Planning
KPI Hierarchy
Align measures to goals
- Flow
Exception-Based Management
Focus on what needs attention
- Quality
Performance Review Cadence
Regular data-driven discussions
- Stability
Feedback Loop Design
Close the information gap
Lock In & Scale
Automate data flow
- Automation
Automated Data Capture
Remove manual collection
- Visibility
Real-Time Dashboards
Instant operational visibility
- Automation
Integrated MES/ERP
Connected information systems
Automation-Eager Factory
Stabilise & See
Assess and stabilise
- Visibility
Automation Audit
Evaluate current technology state
- Stability
Process Stability Assessment
Identify unstable foundations
- Planning
Capability Gap Analysis
Match skills to technology
- Visibility
ROI Review
Honest assessment of returns
Fix the System
Build the foundation
- Flow
Process Simplification
Remove complexity before automating
- Stability
Maintenance Capability Building
Support what you have
- Planning
Right-Sizing Assessment
Match automation to need
- Automation
Integration Planning
Connect systems properly
Lock In & Scale
Targeted automation
- Automation
Phased Automation Roadmap
Sequenced technology adoption
- Automation
Data Integration Layer
Connected automation systems
- Visibility
Performance Analytics
Measure automation effectiveness
Planning-Constrained Factory
Stabilise & See
Understand the gaps
- Visibility
Plan vs Actual Tracking
Measure execution variance
- Visibility
WIP Visualisation
See where work accumulates
- Flow
Lead Time Mapping
Track actual throughput time
- Stability
Constraint Identification
Find the real bottlenecks
Fix the System
Improve flow
- Flow
Batch Size Reduction
Smaller batches, faster flow
- Flow
Pull System Design
Demand-driven production
- Planning
Buffer Management
Strategic inventory positioning
- Planning
Schedule Levelling
Smooth the production mix
Lock In & Scale
Integrated planning
- Automation
Advanced Planning System
Optimised scheduling algorithms
- Automation
Real-Time Schedule Updates
Dynamic plan adjustment
- Visibility
Integrated Demand Sensing
Proactive demand response
Quality-Interrupted Factory
Stabilise & See
Understand quality losses
- Visibility
Defect Tracking System
Count and categorise issues
- Visibility
Rework Measurement
Quantify the cost of quality
- Quality
First-Pass Yield Tracking
Measure right-first-time
- Planning
Quality Cost Analysis
Understand total quality cost
Fix the System
Build quality in
- Quality
In-Process Verification
Catch issues at the source
- Quality
Mistake-Proofing (Poka-Yoke)
Design out errors
- Quality
Root Cause Analysis
Eliminate recurring defects
- Stability
Process Capability Studies
Understand process limits
Lock In & Scale
Automated quality
- Automation
Automated Inspection
Consistent quality checks
- Automation
SPC Systems
Statistical process control
- Visibility
Quality Data Integration
Connected quality metrics
Constraint-Driven Factory
Stabilise & See
Identify and exploit
- Visibility
Constraint Identification
Find the true bottleneck
- Visibility
Constraint Utilisation Tracking
Measure constraint uptime
- Flow
Buffer Status Visibility
Protect the constraint
- Planning
Non-Constraint Analysis
Understand supporting capacity
Fix the System
Subordinate and elevate
- Flow
Drum-Buffer-Rope
Synchronise to constraint pace
- Stability
Setup Reduction at Constraint
Maximise constraint time
- Quality
Quality Focus at Constraint
Never waste constraint capacity
- Planning
Constraint Elevation Plan
Increase constraint capacity
Lock In & Scale
Optimise the system
- Automation
Automated Scheduling to Drum
Optimised constraint loading
- Visibility
Throughput Accounting
Measure true productivity
- Planning
Next Constraint Preparation
Prepare for system evolution
Stable Analog Factory
Stabilise & See
Digitise visibility
- Visibility
Digital Data Capture
Replace paper with screens
- Flow
Process Mapping
Document current workflows
- Planning
Automation Opportunity Assessment
Identify quick wins
- Visibility
Manual Effort Analysis
Quantify administrative burden
Fix the System
Selective digitisation
- Automation
Paperless Work Instructions
Digital guidance at point of use
- Flow
Electronic Travellers
Track work digitally
- Quality
Digital Quality Records
Automated documentation
- Automation
Integrated Data Systems
Connect information silos
Lock In & Scale
Full integration
- Automation
MES Implementation
Shop floor execution system
- Automation
ERP Integration
Connected business systems
- Visibility
Analytics Platform
Data-driven decision support
Automation-Ready Factory
Stabilise & See
Optimise current state
- Visibility
Advanced Analytics Assessment
Identify prediction opportunities
- Planning
Integration Gap Analysis
Find remaining disconnections
- Visibility
Competitive Benchmarking
Understand market position
- Planning
Technology Roadmapping
Plan next-generation capability
Fix the System
Advanced optimisation
- Automation
Predictive Analytics
Forecast before it happens
- Automation
Advanced Process Control
Self-optimising processes
- Automation
Digital Twin Development
Virtual process modelling
- Automation
AI/ML Applications
Intelligent automation
Lock In & Scale
Industry leadership
- Automation
Autonomous Operations
Lights-out capability
- Flow
Supply Chain Integration
End-to-end visibility and control
- Quality
Continuous Innovation Framework
Systematic advancement