Where the money leaks.
Downtime in dollars, not hours. OEE as a financial metric, not «percent uptime». Energy overconsumption as a separate line item. Equipment-as-a-Service — pay for the result, not the CAPEX.
85% is world-class. The average is 55%.
A 30-pp gap means roughly +50% revenue from the same equipment. McKinsey, WEF Lighthouse, Bain — all converge on the same arithmetic. The only question is the toolchain.
Two levers — two P&L lines.
OEE = Availability × Performance × Quality. The gap closes in two moves — each with its own line in the P&L.
First — equipment reliability: fewer stops and emergency repairs, revenue stops leaking on downtime. That is the «Availability» multiplier in OEE — and the first recovered line in the P&L.
Once the equipment is stable, process optimisation kicks in — APC (advanced process control). The asset runs closer to its process constraints: higher yield and quality at the same cost.
Variability is margin you leave on the table. A stable process oscillates less around its setpoint — so it can run closer to the limit without risk.
Both levers run on one infrastructure: the sensors and data that recovered availability become the foundation for optimisation. One investment, not two.
OEE × product price × hours = revenue gap in dollars. See what the plant would yield at world-class 85% versus your current 55%. Per-asset numbers, not «average across the operation».
Every stop is converted into loss — throughput × price × duration. Pareto by asset and by root cause. Investment decisions on a number, not on a feeling.
Motor-current-signature analysis (MCSA) shows which motors run outside the optimum. Bearing wear, supply imbalance, rotor unbalance — all of it is electricity you pay above the curve.
Don't buy the system — pay for the savings it delivered. Base fee + share of verified results + cap. Zero risk for the budget. Bain trend: from 11% to 30% by 2030 — already standard in mature industry.
APC + predictive ROI calculator
Rough estimate against industry benchmarks. The exact number comes after the APC Pilot — 6–12 weeks to establish baseline and pick the optimization method, no commitment.