Shift Loss Review
A focused week comparing planned versus unplanned stops across rotating crews.
Toolkithorizon
We sit with supervisors on Hong Kong floors, classify every stoppage that steals takt time, and leave you with charts your board can act on — manufacturing operations analytics without the theatre.
Stoppage taxonomy
Breakdowns, changeovers, waiting for material, and quality holds named the way your crews already talk about them.
Shift-level truth
Night and day crews compared on the same clock — not averaged into a monthly number nobody trusts.
Board-ready visuals
Simple downtime charts and loss waterfalls that survive a Friday production meeting.
Flagship engagement
Plant Downtime Assessment
A fixed-scope, on-site review for one production area: two weeks of stoppage capture, joint classification with maintenance and production, and a handover pack that shows where minutes actually go. Built for plant managers who already suspect changeovers and material waits — and need evidence the board will accept.
Related work
Other engagements plants book
Production Visibility Board
A physical or screen board that makes OEE losses readable at the cell entrance.
Recurring Floor Support
Monthly check-ins that keep stoppage categories honest after the first assessment.
How we work
From clipboards on the floor to charts the board can argue with
Toolkithorizon does not sell a login screen. We capture stoppages where they happen — beside the press, the filler, or the SMT line — then structure the story so maintenance, production, and finance share one vocabulary.
From recent plants
What supervisors say after the numbers settle
“The downtime map showed us that changeovers on Line B were eating more minutes than we had admitted in the daily stand-up. We still argue about root causes, but at least we argue about the same numbers.”
Mei Ling Chen — Plant Manager, Kowloon electronics assembly
“I wished the first draft of the OEE board had used our local line names instead of generic labels. Once that was fixed, supervisors started marking planned stops correctly within a week.”
Sarah Whitfield — Continuous Improvement, food processing
Ready to name where your minutes go?
Tell us which line or cell hurts most. We reply within two business days with a visit outline for your Hong Kong site.
Request a plant visit