Diagnostic tools
See where your plant is really losing time
10 free calculators, each built around one question from the shop floor. Enter your own numbers and get a clear result, with the scoring explained.
Operational Reliability Check
Your output number is one tile. Add seven more signals from the same month and see whether the plant hit its target calmly or through heroics.
Open the tool480-Minute Diagnostic Lite
Five loss buckets, one answer: how many of today's 480 minutes actually made product, and where the biggest hidden loss sits.
Open the toolSix-Gate Readiness Check
List tomorrow's jobs and tap each gate: pass, fail or unknown. A job is executable only when all six gates pass. Anything else is at risk, however good the schedule looks.
Open the toolWaiting Audit
Watch one line for two hours and log every wait. The audit sorts them into six kinds of waiting and shows which one dominates, and whose move it was.
Open the toolLoss Classification Wizard
Answer up to seven yes/no questions about one stop. The wizard names the kind of loss, who owns it and what usually fixes it. Then re-sort a whole day's “downtime”.
Open the toolProduction Readiness Score
Answer 12 questions about tomorrow's first jobs. You'll see, condition by condition, whether your plan is Ready, At risk or Not ready, and who should act tonight.
Open the tool480-Minute Shift Loss Mapper
Split one 8-hour shift into loss buckets. Run time is whatever is left. The mapper shows how much of the loss your reports can't see, and your largest recoverable bucket.
Open the toolEnd-to-End Reliability Checklist
Follow one typical order past the last machine. Enter how long it waits at each step, then check seven controls. You'll see where OEE stops seeing your system.
Open the toolPlan Stability Assessment
Count last week's plan changes and check how they were handled. You'll get a Plan Stability Index out of 100 and the two fixes that would move it most.
Open the toolMaterial Readiness Checker
The ERP says you have it. Check one job's material against eight layers of readiness, see where it drops out, and keep a tally across jobs.
Open the toolWant a second opinion on your result?
For over a decade, Gemba Concepts has worked with manufacturers on the shop floor. Share what the tool showed you and we'll help you work out what to fix first.