Find the operational losses that matter most
One process. One clear baseline. One prioritised improvement roadmap. For food and beverage manufacturers in Greece, Cyprus and Europe.
- One line, process or value stream
- Evidence from the shop floor
- Prioritised opportunity map
What the diagnostic is
The Food & Beverage Operational Excellence Diagnostic provides a structured assessment of one selected production line, process or value stream.
The objective is to identify the operational losses with the greatest impact and convert them into a prioritised improvement roadmap.
What the diagnostic examines
Safety and food safety
Process discipline, deviations, controls, escalation and operational risk.
Quality
FPY, defects, rework, complaints, variation, process capability and corrective actions.
Delivery
Schedule adherence, lead time, bottlenecks, WIP, interruptions and OTIF.
Cost and resources
Yield, scrap, giveaway, labour, utilities, downtime, energy and water.
People and process
Standard work, ownership, daily management, problem solving and KPI discipline.
Improvement capability
Whether problems are solved systematically and benefits are sustained over time.
The assessment lens
Availability
Where is productive time being lost?
Performance
Is the process operating at the expected rate?
Quality
How much output is lost through defects, rejects or rework?
Changeover
How much capacity is consumed by product transitions?
Yield
Where are raw materials lost?
Flow and resources
Where do material, people, energy or water wait or get used inefficiently?
How it works
- PreparationAgree the line or process, objectives, KPIs, available data and stakeholders.
- On-site assessmentReview the process, management routines, performance indicators and operational losses.
- AnalysisPrioritise findings according to Impact × Evidence × Feasibility.
- Management readoutPresent key losses, improvement opportunities and recommended next steps.
Deliverable: Operational Excellence Opportunity Map
Quick wins
Improvements that can be implemented rapidly with limited analysis.
Focused improvement projects
Lean, Kaizen, SMED, 5S or structured problem-solving opportunities.
DMAIC opportunities
Problems involving variation, unclear causes or significant business impact.
Strategic opportunities
Broader redesign, automation, capability development or management-system changes.
Typical business questions
- Why are we not achieving expected production output?
- Where are we losing material?
- What is driving scrap or rework?
- Which losses are costing us the most?
- Why do some products perform better than others?
- How much time is lost during changeovers?
- What is the real production bottleneck?
- Which problem should we solve first?
- Do we need Lean, Six Sigma, automation or better process control?
Related pathways
Frequently asked questions
What does the diagnostic cover?
One selected production line, process or value stream. Focusing on one area gives a clear baseline and prioritised findings, rather than general observations.
What data do you need?
What already exists: production, quality and downtime indicators, changeover records and material consumption. During preparation we agree which data are available and reliable.
What does the company receive?
The Operational Excellence Opportunity Map, with quick wins, focused projects, DMAIC opportunities and strategic opportunities, plus a management readout.
What happens after the diagnostic?
The company decides. It can implement the quick wins itself, train its team, or start a focused improvement project with our support.
Is our information kept confidential?
Yes. All data and findings are treated as confidential.
Start with evidence.
One process. One clear baseline. One prioritised improvement roadmap.