Measured OEE baseline
Availability, performance and quality losses separated and quantified from real line data — not from an assumed nameplate — so improvement work targets the loss that actually dominates.
S04
Take the plant you already have to the number you were promised.
OEE and site performance programmes for running plants, and conversion of existing sites into digital and sustainability lighthouses. We work from measured data on your line — availability, performance, quality, energy and yield — and stay until the improvement holds through a full production cycle.
- Baseline
- OEE · kWh/t · m³/t · yield · CO₂e/t
- Scope
- Bottlenecks · automation · energy · maintenance
- Benchmark
- WEF Global Lighthouse Network practice
- Engagement
- Diagnostic → programme → verified result
What you get
Bottleneck and debottlenecking plan
Process, mechanical and control constraints identified with load curves and balance work, then a costed modification package ranked by payback.
Energy, water and yield programme
Utility and consumption intensity reduction tied to product quality limits, with TEA and LCA impact quantified for taxonomy and CSRD reporting.
Digital & sustainability lighthouse conversion
Data architecture, use-case portfolio, automation and analytics rollout, and the operating-model change needed for a site to stand up to independent Lighthouse assessment.
How it runs
- 01
Diagnostic
Two to four weeks on data and on the floor: loss tree, OEE baseline, energy and yield mapping, maintenance and operating practice review.
- 02
Prioritised portfolio
Improvement cases ranked by measured impact and payback, split between zero-CAPEX practice changes and engineered modifications.
- 03
Implementation
Engineering, procurement and installation of the modification package, run to the same discipline as our EPCM delivery.
- 04
Verification
Post-change measurement against the baseline over a full production cycle, so the uplift is proven rather than claimed.
- 05
Sustain
Operator training, standard work, dashboards and follow-up support so performance does not drift back after handover.
- Two WEF Global Lighthouse transformations delivered, including mill-wide optimisation of an integrated mill in Asia.
- Across the Global Lighthouse Network, sites have reported step-changes on the order of 50% higher productivity, 80% fewer defects and around 30% lower CO₂.
- Improvement targets are written as contracted KPIs and tested against the measured baseline.
- The same engineers who design plants run the programme, so improvement ideas are executable inside your existing line.
From our own project record
Client, site and product identifiers removed — most of our work is under NDA.
Most plants are not short of ambition — they are short of a measured baseline and someone accountable for closing the gap. That is the whole job here.