Unit cost after month-end
Finance knows the real cost per unit when the month is closed. By then the batch has shipped and the price is fixed.
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Plan, actual and cost per unit in one view
Most plants have the data. It sits in the ERP, the MES, the maintenance system and a dozen spreadsheets, and it rarely agrees. We bring it together so the plant manager and the CFO look at the same numbers.
What we usually find
Three gaps between the floor and the finance office
Downtime and scrap in spreadsheets
Every line keeps its own log. Nobody can say which three stoppages cost the most this month, or what they cost.
ERP and MES never agree
Planned output lives in one system, actual output in another, and the reconciliation happens in someone’s Excel.
What we build
From shift report to board report
OperationsPlant performance dashboard
- OEE by plant, line and shift, with availability, performance and quality
- Downtime by reason, ranked by lost hours
- Plan versus actual output, refreshed during the shift
FinanceCost per unit and margin
- Actual cost per unit against standard, by product family
- Scrap cost and rework in money, not only in percent
- One consolidated view across plants and companies
CustomersDelivery and quality to customers
- On-time delivery and quality complaints by customer
- Defects in parts per million against target
- Premium freight and its causes
MaintenanceMaintenance KPIs
- Mean time between failures and mean time to repair
- Planned versus unplanned maintenance
- Built on data from your maintenance system
KPIs we usually start with
Defined once, used by everyone
- OEE
- Availability
- Performance
- Quality rate
- Scrap rate
- Downtime by reason
- Cost per unit vs standard
- Plan vs actual
- On-time delivery
- Customer PPM
- MTBF
- MTTR
What it can look like
An example scenario
Illustrative scenario based on patterns we typically see. Not a client story: your numbers will differ.
A manufacturer with three plants
About 800 employees, ERP plus a separate MES in each plant.
- Before
- Each plant reports plan versus actual in its own Excel. Cost per unit is known on day 10 of the next month. Month-end close takes 9 working days.
- Health Check found
- 14 shadow spreadsheets, 4 definitions of margin and 2 different OEE formulas in use across the plants.
- After the fix
- One data model over ERP and MES, cost per unit every morning. Close in 4 days, about 60 hours a month of reconciling gone.
- Timeline
- 3-week Health Check, then 12 weeks of fix and build.
Live demo · generated data
Plant performance desk
Three plants, eight lines, one morning screen: OEE, downtime by reason, scrap, cost per unit and delivery to customers, with an AI assistant that answers questions about the numbers.
Start with one plant
A Health Check on one site shows within three weeks where your numbers disagree and what to fix first.