Example deliverable · first step
This is the whole first step, exactly as a client receives it: what their own data gets wrong, priced in money, and what to do about it, in order, with effort and expected effect. Nothing is implemented at this stage. The company below is a rehearsal company, so the numbers can be published; yours would carry your name and your figures.
33 defects · 7 critical · 17 items · 21 BOM lines · 338 sales orders · 158 purchase orders
Deterministic engine. No AI in the decision path. Same input, same output, every figure reproducible from its seed.
Everything critical: loops, orphans, operations that cannot be scheduled. These are not opinions, they are things that make planning mathematically impossible. Nothing here needs new software.
| Action | Why it costs money | Effort | € |
|---|---|---|---|
| Give manufactured items a routing 3 case(s) · sin_ruta |
The item has a BOM but no routing: no times, no capacity, no cost. It is planned as if it were free and instant. Effect: Quoted lead times stop being fiction |
2-3 days | — |
| Close the bill of materials 1 case(s) · bom_huerfano |
A component in the BOM does not exist in the item master. Every MRP run silently skips it, so the part is never ordered and the shortage appears on the shop floor. Fix: create or re-map the component, then re-explode. Effect: Stops unplanned shortages on that product line |
1 day | — |
| Break the BOM loop 1 case(s) · bom_ciclo |
A bill of materials contains itself. Any MRP explosion enters an infinite loop, which is why planning runs either crash or get quietly skipped. Effect: Makes multi-level planning possible at all |
1 day | — |
| Point the routing at a real work centre 1 case(s) · ruta_centro_inexistente |
An operation is routed to a work centre that does not exist, so it can never be scheduled or costed. Effect: Restores capacity planning |
1 day | — |
| Repair the configurator rule 1 case(s) · regla_configurador_invalida |
A sizing rule does not compile or references unknown names, so engineered-to-order quotes fall back to guesswork. Effect: Quotes in minutes instead of days |
2 days | — |
Costs, lead times and supplier performance recomputed from what actually happened rather than what was declared. This is where the money in the table above is recovered.
| Action | Why it costs money | Effort | € |
|---|---|---|---|
| Roll up standard costs from BOM and routing 3 case(s) · coste_incoherente |
The declared standard cost does not match what the BOM plus routing actually add up to. Every quote built on it carries that error, in your favour or against you, and nobody knows which. Effect: Margin per order becomes real instead of assumed |
3-5 days | 18,751 |
| Replace declared lead times with measured ones 6 case(s) · plazo_proveedor_mentiroso |
The declared supplier lead time and the one their deliveries actually show are different. Planning uses the declared one, so purchase orders are raised late and the shortage is blamed on the supplier. Effect: Fewer stock-outs without holding more stock |
2 days | — |
| Fix zero quantities in the BOM 1 case(s) · bom_cantidad_cero |
A component with quantity zero is consumed in reality but not in the system: the stock drifts and the cost is understated. Effect: Stock accuracy and true cost |
1 day | — |
| Fix zero operation times 1 case(s) · ruta_tiempo_cero |
An operation with zero time makes a machine look infinitely fast. Capacity planning around it is meaningless. Effect: Realistic load on the bottleneck |
1 day | — |
| Assign a real gauge to the characteristic 1 case(s) · caracteristica_sin_equipo |
A characteristic is measured by a gauge that does not exist in the register. Effect: Traceable inspection |
1 day | — |
| Correct inverted tolerances 1 case(s) · tolerancia_invertida |
Upper and lower limits are the wrong way round, so the control chart accepts exactly what it should reject. Effect: Real SPC instead of decorative |
1 day | — |
| Remove control plans for items that do not exist 1 case(s) · caracteristica_articulo_fantasma |
Inspection effort is being spent on a part number that is not in the master. Effect: Inspection time back to real parts |
1 day | — |
| Block measurements from out-of-calibration gauges 1 case(s) · equipo_calibracion_vencida |
A gauge whose calibration expired is still signing off parts. Under ISO 9001 clause 7.1.5 that measurement is not valid, and neither is the conformity built on it. Effect: Audit exposure closed |
1 day | — |
| Register and calibrate the unregistered gauge 1 case(s) · equipo_sin_calibrar |
A gauge in use has no calibration record at all. Effect: Audit exposure closed |
1 day | — |
| Point the configurator at real components 1 case(s) · regla_configurador_componente_fantasma |
A configurator rule generates a component that does not exist. Effect: Configured BOMs that can actually be built |
1 day | — |
Calibration that blocks, tolerances that mean something, tooling with a life, dead records retired. Then the same audit runs again and the score is compared: that comparison is the proof the work paid.
| Action | Why it costs money | Effort | € |
|---|---|---|---|
| Retire dead items 1 case(s) · articulo_muerto |
An item with no movement for a long period still carries valuation and clutters every search and count. Effect: Cleaner counts, truer valuation |
1 day | 3,108 |
| Rate suppliers on their own delivery history 5 case(s) · proveedor_incumplidor |
This supplier's on-time record is measurably below what its master record claims. Sourcing decisions are being made on the claim. Effect: Sourcing based on evidence |
2 days | — |
| Merge duplicate records 1 case(s) · duplicado |
The same thing exists twice, so stock and history are split between them. Effect: One truth per part |
1-2 days | — |
| Give the characteristic a tolerance 1 case(s) · caracteristica_sin_tolerancia |
A characteristic is inspected with no limits: the operator decides. Effect: Consistent judgement between shifts |
1 day | — |
| Give tooling a life and a counter 1 case(s) · util_sin_vida |
Tooling is treated as infinite. Two orders can be scheduled on the same tool at the same time, and nobody sees the wear coming. Effect: Fewer surprise stoppages |
2 days | — |
Complete audit of the business and an actionable roadmap. Three weeks. $9,000, fixed. Nothing implemented.
Every process mapped as it actually runs, not as the manual says. Where artificial intelligence pays in your company and, just as important, where it does not. Your master data audited and priced, like the table above. Your own last four months of orders replayed through the decision engine and scored against what really happened. And a roadmap any competent team could execute, ordered by what it is worth.
You can stop there and never speak to us again. Plenty of companies should, and the report will say so when the numbers say so.
For small and medium companies: we execute the roadmap ourselves, and your operation ends up running on the engine instead of on memory and spreadsheets. Priced against your company, from the roadmap you already hold.
Your own people do the work. We teach them the method, hand over the tooling, and step back. From $15,000 for a small technical team. Cheapest for you, and sometimes the right answer.
For medium and large companies that want the capability without hiring it. We are the department: same discipline, same audit trail, monthly scoreboard, and every artefact stays yours. Priced against your company.
The whole thing, handed over automated: purchasing, planning, quality, dispatch, invoicing, credit chasing, deciding inside limits you sign and explaining every decision with the data that triggered it. One box per site for a group.