The assessment is delivered in four structured phases, each designed to progressively strengthen capability, data reliability, analytical depth, and executive decision-readiness. The process integrates walkthrough observation, skill development, tool deployment, data validation, systemic interpretation, and financial quantification.
Phase 1 — Walkthrough & Strategic Alignment
This initial phase establishes a grounded understanding of how the factory currently operates in practice versus how it was intended to perform. Through a full walkthrough of the production floor and support areas, the consultant maps the logic (or lack thereof) driving decisions, flow, responsiveness, and supervision. Early signs of systemic dysfunctions are observed and categorized for further investigation. At the same time, senior management is engaged to align on the scope, boundaries, and data access required for the assessment.
Phase 2 - Capability Development: Engineering for Assessment
Once strategic alignment is achieved, focus shifts to building the internal team’s capacity to conduct meaningful assessments. This phase introduces participants to the modern definition of competitiveness, extending far beyond output or productivity. Teams are then trained in using diagnostic tools that assess flow, methods, changeovers, workforce utilization, and support system responsiveness. Participants also develop the skills to interpret findings systemically, identify root causes, and estimate the business impact of hidden losses.
Phase 3 - Deployment of Assessment Tools with Coaching
With skills in place, teams deploy the full assessment toolkit inside the factory under close consultant supervision. Tools are applied across departments to measure actual workload distribution, flow rhythm, balancing logic, method reliability, changeover efficiency, and support team responsiveness. The consultant ensures all data collected is accurate, fact-based, and consistent. Each result is then interpreted in context and synthesized into indexed scores reflecting agility, efficiency, optimization, and system reliability.
Phase 4 - Consolidation, Analysis & Financial Potential Mapping
The final phase transforms operational observations into executive clarity. Findings are grouped under the six systemic gap categories defined by SmartLean Agility™. Using heat maps and priority matrices, the factory’s loss profile is visualized. The financial consequences of each systemic weakness are quantified — including SMV leakage, cost-per-minute loss, manpower inefficiencies, quality-driven rework, and agility drag. These results are compiled into a comprehensive Systemic Gap Report for leadership.
