3 days of on-site vision in the hall

We don't look for errors in spreadsheets, but at the machines

Most advisors ask for system access and analyze charts in an air-conditioned office. We do it differently. For 3 days, Marek or Robert are part of your hall. We don't come to lecture operators. We stand aside with a stopwatch and a notebook. We observe how material flows and where bottlenecks form, which the production manager often has no idea about. We know the smell of grease and know that textbook theory rarely fits the Polish production reality.

Last month, at a plant near Grójec, we noticed that CNC machine operators lose an average of 11 minutes on each changeover. Why? Because the wrenches and holders were in a cabinet on the other end of the hall. With 7 machines and two shifts, that's concrete money thrown down the drain. Such details aren't visible in Excel. They are only visible when one spends 8 hours by the line, watching hands and worker movements. We count every penny because we know margin escapes in such trifles.

What exactly do we do during these 72 hours?

• We measure actual cycle time at 4 key workstations.
• We check how much time employees lose searching for documentation or tools.
• We analyze logistics – whether forklifts are driving empty for 34% of shift time.
• We talk to people at the machines, because they know best what's blocking them.

Honestly, after the first day, we often hear from owners that "it's always been this way here." After the third day, when we show on paper that a simple change in the arrangement of two tables will recover 14% of free space, the approach changes. No fluff – you get a list of specifics from us that can be fixed from Monday. You don't need expensive IT systems for this, just good work organization and eliminating unnecessary steps.

Sometimes our presence is stressful for the crew, so we ensure a normal atmosphere. We aren't a government inspection, just support for the company. We explain to workers that we are looking for improvements for them, not reasons for layoffs. Floor specifics are the basis of our work. At the end of the visit, you receive a report that is 4 pages long – just facts and figures, without unnecessary talk about vision and mission.

Heads-up: We don't take more than 2 such audits a month. We want to ensure Marek personally checks every machine and doesn't overlook any bottleneck. Thanks to this, our recommendations are accurate in 93% of cases at the first implementation.