DATASHEET
Factory Profit Audit
Like to Know?
1. How much $ extra capacity is available from my
current lines without spending capital?
“
2. How many more cases can we produce with the
same plant and workforce?.
3. How much less could we spend on Labor,
Materials and Energy to produce the same
volume?
4. How much $ improvement can be made within
12 weeks?
“The Factory Profit Audit established a very
specific performance target for each site and
set a clear implementation roadmap that
should enable us to begin delivering financial
benefits within 12 weeks from project
commencement. I fully expect to realize
substantial efficiency savings within months
of starting the project.
Managing Director
of Operations from Intersnack
“
Like to know?
The 3-day Audit will:
• Set EBIT expansion improvement targets
• Quantify immediate cost saving opportunities
• Benchmark against the leaders in the industry
• Rank and prioritize improvement focus
utilizing the greatest continuous tool available to you: the
hourly paid workforce.
Using a library of industry statistics the Factory Profit Audit
provides an analysis of the plant’s true operating efficiency
compared to their ‘reported’ efficiency. It provides a
• Quantify the improvement potential of their hourly paid
benchmark of how they measure up against the leaders and
• Catalogue quick win opportunity areas
laggards in the industry and identifies those areas that can be
improved the fastest, at the least cost, and with the greatest
The Factory Profit Audit will identify exactly where the
impact.
financial gains are hidden within each plant before a
dime is spent.
The 3-day activity establishes specific performance
Apteans’s 3-day Factory Profit Audit, specifically aimed at
improvement targets, introduces common factory metrics
addressing the needs of process-intensive manufacturers is
such as Overall Equipment Effectiveness (OEE), and provides a
focused on a set of EBIT expansion objectives designed to
framework to assert ownership for plant performance at the
deliver improvements within 100 days. It is a profit-related
workplace level that takes weeks, not years to implement.
audit that identifies those aspects that directly impact
The audit delivers a detailed execution plan designed to drive
manufacturing cost margins. Recommendations are focused
a step change in performance within 100 days.
on actions that require minimal capital consumption and
establishes an agenda for rapid performance improvement
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ebusiness suite
Audit Deliverables
• “Real” performance of plant compared to
reported performance
“
• An executive summary of EBIT expansion
opportunities
• $ Value of the gain that can be delivered in 100
“The Factory Profit Audit turned out to be a
real catalyst. It highlighted pretty significant
inaccuracies in our measures. The part where
the fastest gaps could be addressed was
great, as it gave our people an immediate
way of making a difference in weeks not
months. I would recommend it to others who
own and run food businesses.
“
days.
• A 100-day EBIT improvement execution program
• Catalogue quick win opportunity areas
Greg Hoffman
VP Manufacturing. American Popcorn Company
• A benchmark comparison between industry
Leaders & Laggards
George Jurkovich
SVP, Operations, Bay Valley Foods
“
“
“The Factory Performance Audit and
Benchmark was a great reality check on our
manufacturing performance across the plant
network. It kick-started our enterprise–wide
change program with a clear ROI focus,
realistic but challenging targets, and a ‘can
do’ mentality. I would strongly recommend
anyone who is considering any continuous
improvement initiative carry out the audit.
Factory Profit &
Benchmark Audit Study
Background
The foundation of the Factory Profit Audit is a comprehensive
study performed by Aptean through more than 80 on-site
business analyses over the course of two years. The study,
which explored food and beverage plants’ current challenges
and approaches to driving productivity, not only concentrated
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on existing data gaps and plant performance, but also
uncovered the significant opportunity available from the
hourly paid workforce. Using a hands-on approach, the on-site
study included an in-depth examination that spanned from the
executive level to the shop floor. The study findings have now
been brought together into an industry-wide scorecard and
benchmark index.
Typical Factory Profit
Audit Agenda
Day One and Two: Data Gathering
Aptean experts measure the true plant performance compared with
the ‘reported’ performance. Armed with this, the team identifies
gaps and margin improvement opportunities which is then mapped
to the budgetary and costing structure of the organization to
quantify the financial opportunity. This results in a summary of the
potential EBIT opportunity available from the plant’s current people,
process and plant infrastructure. This is then prioritized into a 100
day EBIT improvement program.
Theses drivers produce an Overall Factory Performance Score ranked
in relation to the established Benchmark Index based on 80 food
and beverage plants. In addition, the company receives a summary
scorecard of plant performance for each driver against the best-inclass leaders—those that have mastered the eight drivers—and the
laggards in the industry.
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Day Three: Summary & Review
The team delivers an Executive level summary analysis of the
financial opportunities available alongside the plant’s current ‘real’
operating performance. Presented in simple terms it is a no’ holds
barred’ review of the current and potential future state achievable
within weeks from program commencement.
Aptean experts also introduce Factory technology as an enabler
to unlock these opportunities with out-of-the box performance
metrics, daily performance review structures, standardized daily
best operating practices, and change management helping
manufacturers produce and sustain immediate bottom line results.
With a closed-loop continuous improvement approach, companies
will permanently lower the cost of production with the ability to
enforce discipline and accountability, identify opportunities for
ongoing operational improvements, monitor action, and measure
the daily impact on the business.
Schedule a Briefing
Today
Contact Aptean to discuss how the Factory Profit
Audit can ignite your margin improvement initiatives.
Call +1 770 351 9600 or email: [email protected].
Visit www.aptean.com to learn more.
More than 9,000 customers around the world rely on us to give them a competitive edge. By
providing innovative, industry-driven enterprise application software, Aptean helps businesses
to satisfy their customers, operate most efficiently, and stay at the forefront of their industry.
For more information, visit: www.aptean.com
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