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Production Loss & Downtime Investigation
The plant was running. It just was not producing.
Output below plan, lines that stop and start, targets missed every month for reasons nobody can pin down. We investigate production loss and downtime across textiles, FMCG, pharma, cement and manufacturing, and find the few causes behind most of the lost output.
Discuss this with us
Since the 1990s
30
years investigating
250+
investigations closed, incl. HiPOs
15
countries served
20+
countries of lead seminars
100+
nationalities trained
B1 · WHERE DID THE OUTPUT GO?
Where did the output go? Choose a case.
THE LOSS
Line stops 30 times a shift.
WHAT WE USUALLY FIND BEHIND IT
Most stops are short and unrecorded; three causes account for most of them.
Illustrative cases, typical of what production loss & downtime investigation uncovers.
B2 · WHAT WE LOOK AT
The plant was running. A first call costs nothing, and we will tell you what the evidence needs to show.
B3 · ONE INVESTIGATION, MANY FINDINGS
You commission one investigation. You get a review of the whole system.
A typical example, based on many investigations. Not a single client’s case.
The P3i approach
How we investigate production loss. Fact-finding, not fault-finding.
Every P3i investigation is led by a senior investigator and supported by internationally qualified process specialists. You will not receive a list of people to blame, or a long list of generic actions. You will receive the facts, the proven causes, and a short plan that closes the gaps, in this case and across your system.
Independent
No products, repairs or contracts to sell you afterwards.
Senior-led
Thirty years of investigation, from the first call to the final briefing.
Beyond the event
Process specialists find the other cracks before they fail.
Ready to present
Written for boards, buyers, insurers and regulators.
How P3i does it for you
- 01
Measure the loss
Output, downtime and speed losses.
- 02
Find the biggest stoppages
By line, shift and cause.
- 03
Prove the causes
Maintenance, materials, planning and skills.
- 04
Put a number on it
Lost output and cost per month.
- 05
Recover capacity
Targeted actions with owners and a follow-up measure.
What you receive
Call us when
Free 30-minute case assessment.
Tell us what happened. In confidence, we will tell you what the investigation should cover, how long it will take and what to preserve today.
How we work with you
What happens after you call.
For a production loss & downtime investigation, the first call covers what has happened, which records exist and who needs to be involved. From there, this is the usual pattern.
First hour
A call with a lead investigator. You leave it knowing what to preserve today and who to call next.
Day one
An investigator on site, anywhere in Pakistan. Scope and fixed fee agreed in writing.
Week one
A private briefing on early findings, so urgent risks are dealt with before the report is finished.
Weeks three to four
The final report, the wider system review and a remedial work plan, presented to your team.
After
We come back to check the actions were completed and actually worked.
Typical timings for a single-site event. Complex, multi-party matters take longer, and we tell you so on the first call.
What you receive
A full investigation report. This is only its first page.
The summary is what leadership reads first. Behind it sits the complete file: every witness heard, every document and record examined, and every finding tied to numbered evidence, so a board, an insurer, a buyer or a regulator can test it.
1 · Established sequence
2 · Causes
3 · Wider system findings
4 · Remedial work plan
Illustrative summary page. Report length and structure depend on the scope of each case.
Inside the full report
- 01Executive summary SHOWNThe findings and actions leadership needs, on one page. This is the page shown here.
- 02Terms of reference & scopeThe questions asked, the boundaries of the investigation and who commissioned it.
- 03MethodHow evidence was gathered, and which analysis methods were chosen for this case, and why.
- 04Verified chronologyThe sequence of events, reconstructed from records, data and accounts, minute by minute where it matters.
- 05Site & technical examinationScene, equipment, failed parts, measurements and photographs, with specialists where needed.
- 06Witness evidenceInterview schedule, accounts in summary, and where the witnesses agree and where they conflict.
- 07Documents & recordsPermits, procedures, maintenance, training, rosters, CCTV, tracker and control-system data reviewed.
- 08Causal analysisImmediate, underlying and system causes, each one tied to numbered evidence.
- 09System reviewWhere the same weaknesses exist elsewhere in the operation.
- 10Findings & conclusionsWhat is proven, what is probable, and what remains open, stated plainly.
- 11Recommendations & work planTargeted actions, each with an owner, a date and a test of whether it worked.
- 12AppendicesEvidence register, photograph log, interview records, drawings and data extracts.
Every action has an owner, a date and a test of whether it worked. The evidence stays indexed, so any reader can check how each conclusion was reached.
From our files
See all 16 cases → Client names, people, locations and dates removed.
QUESTIONS
What leadership teams ask us first.
How is this different from Time Loss?
Time Loss looks at where the hours go. Production Loss looks at output: what should have been made and was not.
Do we need special data?
No. We use what you have and measure on the line where records are thin.
Will you train our team to do this?
Yes. We can train your team to run the same analysis themselves.