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SAMPLE ROADMAP
Company type
Contract CNC manufacturer
Plant size
85 employees
Current stage
2: Stabilizing
Ceiling blockers
P1, P5
EBITDA OPPORTUNITY IDENTIFIED
$531K-$830K
Annual, based on the sequenced actions below. Based on typical results for a plant of this size with these ceiling constraints.
PILLAR SCORECARD
P1
People & HR
1
BLOCKING
P2
Safety
2
P3
Training
2
P4
Daily Mgmt
2
P5
Planning
1
BLOCKING
P6
Quality
2
P7
Equipment
2
P8
Problem Solving
2
P9
Financial
1
P10
Strategy
2
P1 People and P5 Planning are both ceiling pillars at Stage 1. This caps the overall plant stage at 1: Surviving, until those two advance. That is why the first 30 days focus on People and Planning foundations.
90-DAY ACTION PLAN
P1
Build and distribute a written attendance policy
$45K-$65K
EST. ANNUAL IMPACT
Define expectations, call-in procedures, consequences. Distribute to every employee. Get signed acknowledgment.
Guide: HR-01 Attendance Policy
P1
Launch a referral bonus program
$28K-$42K
EST. ANNUAL IMPACT
$500 per successful 90-day hire. Announce at all-hands. Track referrals in HRIS or spreadsheet.
Guide: HR-02 Referral Program
P5
Install daily production meeting cadence
$120K-$180K
EST. ANNUAL IMPACT
15-minute standing meeting at shift start. Standard agenda: yesterday results, today plan, roadblocks. Every supervisor attends.
Guide: P5-02 Daily Meeting Framework
P2
Deploy near-miss reporting and weekly safety walks
$28K-$42K
EST. ANNUAL IMPACT
Near-miss form in every area. Weekly 30-minute walk with rotating supervisor. Findings tracked and closed within 2 weeks.
Guide: P2-01 Safety Walk Protocol
P9
Implement job costing visibility by product line
$85K-$140K
EST. ANNUAL IMPACT
Pull the last 60 days of labor and material by job. Map to product line. Identify which products are actually making money.
Guide: P9-01 Job Costing Basics
P6
Deploy 5-Why root cause analysis for top 3 defect types
$60K-$95K
EST. ANNUAL IMPACT
For each recurring defect, convene a 1-hour 5-Why session with operator, supervisor, and quality. Document and test the fix.
Guide: P6-03 Root Cause Analysis
P3
Build operator skills matrix and training tracker
$35K-$55K
EST. ANNUAL IMPACT
Map every operator to every operation. Identify single points of failure. Plan cross-training to eliminate the top 5 gaps.
Guide: P3-01 Skills Matrix
P2
Document and train incident investigation process
$15K-$25K
EST. ANNUAL IMPACT
Standard investigation form. Train supervisors on 5-Why and fishbone techniques. Review every recordable within 48 hours.
Guide: P2-02 Incident Investigation
P4
Install supervisor accountability boards
$42K-$68K
EST. ANNUAL IMPACT
Daily metrics board per shift. Plan vs. actual for output, quality, safety, attendance. Supervisors update before shift handoff.
Guide: P4-02 Accountability Boards
P7
Preventive maintenance schedule for top 5 constraints
$55K-$85K
EST. ANNUAL IMPACT
Identify 5 machines that cause the most downtime. Build PM schedule. Assign ownership. Track PM completion weekly.
Guide: P7-01 PM System Basics
P4
Standardize shift handoff SOP
$18K-$30K
EST. ANNUAL IMPACT
10-minute overlap between shifts. Standard handoff form covering jobs in progress, quality issues, equipment status, safety concerns.
Guide: P4-03 Shift Handoff
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