Continuous Improvement (CI) Managers in manufacturing are under constant pressure to optimize performance, reduce costs, and increase throughput. However, many improvement efforts fall short—not because of a lack of effort, but because they focus on the wrong issues, rely on outdated data, or struggle to engage frontline teams.

This playbook outlines how manufacturers can overcome these barriers by using real-time, machine-level insights to identify true root causes, engage operations, and unlock hidden capacity.

Key Takeaways for Manufacturers:

Solve What Really Matters

• Avoid wasting resources on the most visible—but not necessarily the most impactful—problems
• Identify hidden performance drains like speed loss and micro-stoppages
• Prioritize initiatives based on real-time impact, not assumptions

Replace Assumptions with Accurate Data:

• ERP targets and spreadsheets often mask inefficiencies
• Use Top Historical Speed (THS) to uncover true machine potential
• Set smarter standards and detect speed variability early

Engage Operators in the CI Journey

• Lack of frontline engagement can stall even the best strategies
• Empower operators with visual tools, feedback loops, and performance visibility
• Make CI a collaborative effort between leadership and operations

Results You Can Expect:

Reclaim thousands of production hours

• Optimize job speeds and eliminate unnecessary slowdowns
• Increase output—without investing in new equipment
• Build a continuous improvement culture grounded in transparency and accountability