Factory diagnostics
Diagnose the operation before choosing the technology
A useful factory diagnostic follows material, information, decisions and cash through the real operation. It does not begin with a software demonstration.
1. Map the operating flow
Walk the process from enquiry and order acceptance through procurement, stores, production, quality, dispatch, invoicing and collection. Record where information is re-entered, approvals wait, material loses identity or teams keep shadow spreadsheets.
2. Test master-data discipline
Review item codes, units of measure, bills of material, routings, customer and supplier records, machine data and quality specifications. Duplicate or incomplete master data weakens every report built above it.
3. Reconcile material and WIP
Compare physical stock with system stock, then trace selected jobs through material issue, production stages, subcontracting, rejection, rework and finished goods. Differences reveal where transactions do not match reality.
4. Examine planning and exceptions
Check how priorities are set when material is late, machines are unavailable, quality holds occur or urgent orders enter the plan. A workable system must make exceptions visible and assign responsibility.
5. Connect operations to financial impact
Translate delays, excess stock, scrap, rework, overtime and missed dispatches into measurable business impact. This creates a roadmap based on value and control, not feature count.
What the roadmap should contain
Finish with named process owners, immediate control fixes, master-data work, system changes, integration needs, adoption actions, success measures and a phased sequence. That provides a defensible basis for investment.