Articles & guides

The losses hide in the rhythm.

Manufacturing intelligence from the floor, drawn from a study of interruptions across 12 operations and 62 production lines. Named frameworks, hard numbers, and how to find the capacity you're already paying for.

Whitepaper
The Interruption Whitepaper
A study of production interruptions across 12 manufacturing operations and 62 lines. The average time between interruptions is 1 minute 14 seconds, and closing the gap to a stable pulse is worth up to 4.89% of total OEE.
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Efficiency
The Speed Tax: why faster machines don't recover lost capacity
Volatile lines don't run slow because the machines are slow. They run slow because they're constantly stopping and restarting. That fragmentation carries a measurable 12.54% performance penalty you can't buy your way out of.
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Metrics
MTBI: the 74-second pulse of production
Mean Time Between Interruptions is the heartbeat of a line. Across 62 lines it averages 1m 14s, an exhausting stutter of constant micro-stops. Here's what MTBI measures, and why moving it to 3m 27s changes everything.
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Benchmarking
The three tiers of operational health
Optimised, Critical, Volatile. Using a 14.28% interruption-ratio baseline and a 19.82% upper control limit, every line falls into one of three bands, and the band tells you whether you're paying a speed tax.
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Data quality
The buffer illusion: how stop-thresholds hide your real losses
A line reporting a tidy 12.86% interruption rate can be hiding a 15-second time-between-stops. Lenient stop-thresholds act as an administrative mask. The Threshold Exposure Index strips it away.
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