Executive summary
Analysis of 847 production records and 312 inventory SKUs identified three material profit leaks totalling an estimated $282,000 in annual preventable losses. The highest-priority finding — yield loss concentrated on Line 2 during afternoon shifts — represents a single calibration issue recoverable in 1–2 weeks. The dead stock position requires a disposition decision within 30 days to prevent additional carrying costs.
Recommended actions — by owner
Plant Manager — this week
Recalibrate filler heads on Line 2 at the start of the afternoon shift. The data shows filling loss is 61% concentrated in PM production runs — calibration drift post-lunch cycle is the most probable cause. Target: recover $93K/yr of the $142K annual yield loss.
Inventory Planner — within 30 days
Freeze replenishment on all 23 dead stock SKUs. Convene a disposition review — clearance pricing for 15 SKUs, supplier return negotiation for 5, write-off authorization for 3. Release approximately $43K of working capital in the first round.
Procurement — before next contract renewal
Renegotiate GlobalChem Asia pricing — the 7.8% unfavorable variance has been consistent for 4 months, suggesting a structural issue rather than a spot price spike. The renegotiation window opens in 90 days. Prepare a benchmark comparison now.
🔒 Analysis performed locally in the browser from a CSV export. No business data transmitted to any server. Confidence: high (847 rows, complete production log for the period).