OUTCOME · COST VISIBILITY

True cost. Real time.

Activity-based costing wired to actual production data. You stop arguing about averages and start managing real cost per part, per line, per shift — with finance and ops finally reading from the same numbers.

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── WHEN THIS IS FOR YOU ──

01

You don't trust your line-level cost numbers.

Standard costing rolls up clean — and hides where the money is actually leaking. The variance ledger is a horoscope, not a tool.

02

Pricing decisions feel like guesses.

You're quoting against a cost model that was true two years ago and an SKU mix that's drifted three times since. Margin is the residual, not a target.

03

Finance and Ops disagree about the same line.

One says the line is profitable. The other says it's bleeding. Neither has the data to settle it — so the meeting ends with another spreadsheet.

04

You can't tell which SKU is actually carrying the plant.

Or which one is silently subsidized by the rest. The mix decisions you should be making, you can't.

── WHAT YOU GET ──

Outcomes, not deliverables.

01 · OUTCOME

Real-time cost per unit

Live cost calculated against actual production, materials, labor, and downtime — not last quarter's averages.

02 · OUTCOME

Line- and SKU-level transparency

Margin visible at the resolution where you can actually act on it. The conversation moves from 'this plant' to 'this line on this shift.'

03 · OUTCOME

Activity-based cost model wired to OT

Costs tied to real activities, real volumes, and real downtime — sourced from the floor systems, not retyped into a finance spreadsheet.

04 · OUTCOME

Variance you can act on

Not month-end surprise. Same-day signals when material yield, labor utilization, or downtime drift the cost model meaningfully.

05 · OUTCOME

Pricing leverage

Quote, mix, and capex decisions backed by current cost data. The conversation with sales and finance changes immediately.

06 · OUTCOME

Finance / Ops alignment

Same numbers, same source, same definition. The standing argument about whether the line is profitable goes away.

── HOW WE DELIVER IT ──

Cost visibility is a data problem, an integration problem, and a finance-process problem at the same time. We deliver across all four modes; most engagements blend Strategy + Integration with a Rapid Impact entry point.

STRATEGY & OPERATIONS

Stop chasing buzzwords. Start solving real problems.

When the question is what to do, in what order, with what budget, and to what end. We translate operational ambition into a sequenced, fundable plan that survives contact with the shop floor.

  1. 01 · LISTENTwo weeks on the floor, in the data, and with leadership. We earn the right to make recommendations.
  2. 02 · FRAMEMap the constraints — physical, informational, organizational — and surface the trade-offs.
  3. 03 · SEQUENCERank initiatives by leverage, cost, and risk. Plan written in your team's language, not ours.
  4. 04 · SHIPFirst initiative goes live. Success is measured on the line, not at the steering committee.
DIGITAL INTEGRATION

Everything between the PLC and the P&L.

OT/IT integration, MES, historians, and the connective tissue that turns shop-floor signals into decisions on the floor and numbers in the boardroom.

  1. 01 · DISCOVERMap systems, signals, and decision points. Where is data created? Where does it need to go? Where does it get lost?
  2. 02 · ARCHITECTDesign the integration layer around your use cases — not a vendor's reference diagram. Standards where helpful, pragmatism where required.
  3. 03 · BUILDConnect equipment, configure platforms, write the bespoke pieces. Working in your environment, with your team alongside.
  4. 04 · OPERATEHand off with documentation, training, and a sustainment plan so the system stays a system that runs.
RAPID IMPACT · RIOT KIT

Weeks, not quarters.

Productized engagement built for ops leaders who want a focused, measurable win on a real line — before signing up for a multi-year transformation. Narrow scope. Fixed timeline. Outcome you can see from the floor.

  1. 01 · SCOPEHalf-day session. We pick the line, the constraint, the metric, and the win condition. In writing, before we start.
  2. 02 · INSTRUMENTBaseline data. Whatever's missing to measure honestly, we add — working from your existing systems where possible.
  3. 03 · INTERVENEThe actual change: control tweak, dashboard, integration, operating ritual. Whatever the constraint demands.
  4. 04 · REPORTBefore-and-after on the agreed metric. Honest read. Recommendation on what to scale, what to leave, what to retire.
LIFECYCLE

The system you bought last year should still be earning.

Adoption, training, and sustainment so the platform you funded keeps shipping value. Most manufacturing software dies of neglect, not bad design — we keep yours alive.

  1. 01 · ASSESSAudit the system, the team, and the operating rituals. Where is value leaking? What broke after go-live?
  2. 02 · STABILIZEFix what's broken, retire what isn't earning, retrain what wasn't learned. Get to a clean baseline.
  3. 03 · EMBEDMake the system part of the daily-management ritual. Operators, supervisors, and ops leadership all see themselves in it.
  4. 04 · EXTENDSmall, scoped enhancements every quarter — guided by what's actually moving the metric, not by feature backlog.
CASE STUDY · [CUSTOMER NAME]
“[Customer quote — to be sourced from a cost-visibility engagement that turned a standard-cost spreadsheet into real-time activity-based decisions.]”
— [NAME, ROLE], [CUSTOMER]
READ THE FULL CASE ▶
OUTCOME

[XX%]

[Margin recovered or mispriced-SKU loss eliminated — to confirm]

── FAQ ──

We already have an ERP. Why isn't that enough?
ERPs are great at recording transactions and rolling up standard costs. They're not built to reflect what's actually happening on the line in the last 15 minutes. Activity-based costing needs the OT layer feeding it — that's the gap we close.
Do we have to replace our finance system?
No. Most engagements leave the finance system in place and feed it cleaner, more granular data. The cost model lives where it should — between the floor and the ledger.
How long does this take to stand up?
A scoped pilot on one line typically delivers usable real-time cost inside 8–12 weeks. Plant-wide rollouts are sequenced; we don't recommend trying to do it everywhere at once.
What's the relationship between cost visibility and our existing dashboards?
They're the same data layer, sliced differently. The cost view sits on the same instrumented platform as throughput, yield, and downtime — same numbers, financial lens.
Will operators see cost data?
By role. Operators see the production metrics they can act on. Supervisors see line-level cost behavior. Plant and finance see the roll-up. The granularity is matched to the decision each role actually owns.

Ready to stop pricing on guesses?

30 minutes, working session. Bring the cost question that hasn't had a clean answer and we'll walk you through how we'd build it.

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