11. The Silent Profit Killers
Stop paying for urgency, expediting and firefighting
PPC Journey 12 of 18
The Sustainable Factory
The best factory creates great products without consuming great people.
Deliver on time without depending on overtime and heroics
Profit and people
What this journey is about
Many factories believe more hours mean more production. The factory that never sleeps often depends on a few heroes who carry every crisis.
Fatigue doesn't appear on the balance sheet, but it shows up in errors, rework, attrition and the families behind every shift.
This journey makes overtime a business choice instead of a management habit, through realistic plans, balanced loading and finishing on time.
Key idea
Overtime should be a business choice, not a management habit.
Where we look in your plant
Episodes
8 episodes
Each episode follows one factory story, the business numbers behind it, and one action for Monday morning.
- EP 01The Factory That Never Slept
- EP 02The Hidden Cost of Heroism
- EP 03Fatigue Doesn't Appear on the Balance Sheet
- EP 04The Day We Finished on Time
- EP 05Productivity Is Not Measured in Hours
- EP 06Families Are Silent Stakeholders
- EP 07The Factory That Respected Time
- EP 08The Sustainable Factory
Next step
Does this sound like your plant?
We measure where your plant stands today, agree the target with you and work alongside your team until it is reached. We charge on success fees.
Continue the series
Previous and next journey
13. The Invisible Defect
Build quality into the process, first time right
FAQ
Frequently asked questions
What is PPC Journey 12, The Sustainable Factory, about?
Many factories believe more hours mean more production. The factory that never sleeps often depends on a few heroes who carry every crisis. Fatigue doesn't appear on the balance sheet, but it shows up in errors, rework, attrition and the families behind every shift. This journey makes overtime a business choice instead of a management habit, through realistic plans, balanced loading and finishing on time.
What is the key idea of The Sustainable Factory?
Overtime should be a business choice, not a management habit.
Which episodes are in The Sustainable Factory?
The Sustainable Factory has 8 episodes: The Factory That Never Slept, The Hidden Cost of Heroism, Fatigue Doesn't Appear on the Balance Sheet, The Day We Finished on Time, Productivity Is Not Measured in Hours, Families Are Silent Stakeholders, The Factory That Respected Time and The Sustainable Factory.