The full capability set.
A detailed look at what we do across all three pillars. Engagements are scoped to your situation — most span more than one pillar. Use this as a reference for the depth behind each area.
All Capabilities
More capability areas are being added. Detailed breakdowns by pillar continue below.
Pillar 01
Operations
Assess, stabilize, and optimize how your plant runs — from floor-level execution to management systems.
Operational Assessments
- Full-scope facility operational assessments using a structured six-phase methodology
- Reliability Maturity Scorecard — 1-to-5 scoring across six domains to baseline current state
- Production efficiency analysis — OEE measurement, bottleneck identification, throughput modeling
- Shift structure, staffing adequacy, and labor utilization reviews
- Management of change (MOC) program evaluation
- Standard operating procedure (SOP) review and gap identification
- Management system assessment — KPIs, reporting structure, accountability frameworks
Process Optimization
- Process flow analysis and constraint identification
- Waste reduction — material yield, energy, water, downtime
- Changeover optimization and scheduling improvements
- Cold storage, warehousing, and logistics workflow design
- Capacity modeling and scenario planning across production lines
- Utility system optimization — compressed air, steam, refrigeration, wastewater
Performance Management Systems
- KPI framework development — production, maintenance, quality, safety, cost
- Daily / weekly / monthly management review cadence design
- Visual management and Gemba board implementation
- Shift handoff and communication protocols
- Cost tracking and budget variance reporting systems
Compliance & Permitting
- OSHA compliance program review and gap closure
- Environmental permitting and compliance coordination (wastewater, air, stormwater)
- Emergency action plans and incident response procedures
- Contractor safety management programs
- Building code and occupancy classification coordination
Startup Operations
- Staffing plans — organizational design, job descriptions, hiring timelines
- SOP development across all functional areas
- Training program development and delivery — operations, maintenance, quality, safety
- Shift structure design and scheduling
- PO and procurement authorization hierarchies
- Budget development — operating budgets, startup cost tracking, variance reporting
- Capital project management — scope, schedule, budget, vendor coordination
- Commissioning and startup planning — phased equipment qualification, utility startup, process validation
Turnaround Operations
- Fast-track operational assessment — critical failures, safety risks, and production blockers within the first 1–2 weeks
- Triage and prioritization — immediate actions vs. near-term vs. structural fixes
- Interim management support — embedded on-site leadership during transition or crisis periods
- Production schedule stabilization and throughput recovery
- Staffing assessment and rapid hiring / training support
- Cost containment and budget rebuild
- Vendor and contractor re-engagement and contract renegotiation
- Stakeholder communication — executive updates, board reporting, customer communication frameworks
- Transition planning — handing back to permanent leadership with documented systems and trained personnel
Pillar 02
Reliability
Build maintenance organizations and programs that keep your assets running — not just reacting. Data-driven, disciplined, and designed to last.
Maintenance Department Build-Out
- Organizational design — staffing plans, role definitions, skill requirements, reporting structure
- Technician assessment and selection — multicraft evaluation, skills gap analysis
- Craft specialization vs. multicraft strategy — right-sizing the team to the asset base
- Contract labor strategy — when to use, how to manage, agreement review
- Training program development — technical skills, safety, compliance, OEM-specific
- Maintenance budget development and cost tracking
Reliability-Centered Maintenance (RCM)
- Full RCM analysis for critical and high-consequence assets — functional failure identification, FMEA, consequence evaluation, and task selection
- RCM-based strategy assignment — run-to-failure, time-based, condition-based, or redesign per failure mode
- Failure mode and effects analysis (FMEA) — failure modes, causes, effects, severity, and detection capability
- Criticality analysis — asset ranking by consequence of failure (safety, environmental, production, cost)
- PM optimization — align existing PM tasks to RCM logic and actual failure patterns
- Age exploration and actuarial analysis — justify time-based intervals vs. condition-based approaches
Preventive & Predictive Maintenance
- PM program development — time-based, usage-based, calendar-based, and condition-triggered task libraries
- PdM design and implementation — vibration analysis, infrared thermography, oil analysis, ultrasonic testing, motor circuit analysis
- PdM technology selection and vendor evaluation — in-house capability vs. contracted services
- Precision maintenance — alignment, balancing, lubrication, torque specs, installation standards
- Lubrication management — route design, consolidation, contamination control, automated systems
- Calibration programs — instrument registers, schedules, tolerance standards, traceability
CMMS Implementation & Optimization
- CMMS platform selection — requirements definition, vendor evaluation, implementation planning
- Asset hierarchy and equipment register — functional locations, parent-child, nameplate data, criticality
- PM / PdM task library buildout — procedures, frequencies, parts lists, labor estimates, craft assignments
- Work order workflow design — request, prioritization, approval, planning, scheduling, execution, closeout
- Planning and scheduling process — weekly / daily scheduling, backlog management, schedule compliance
- Spare parts and MRO strategy — criticality-based stocking, min/max, VMI, consignment, obsolescence
- CMMS data migration and legacy system transition
- CMMS health assessments — data quality, workflow compliance, user adoption, reporting effectiveness
Maintenance Operational Processes
- Work identification and prioritization — emergency vs. urgent vs. routine vs. planned
- Job planning standards — task steps, parts kitting, tools, permits, safety procedures, duration
- Weekly and daily scheduling discipline — frozen window, break-in management, schedule compliance
- Backlog management — aging analysis, composition, ready-to-schedule, reduction strategies
- Shutdown and outage planning — scope, critical path, resource loading, parts staging, contractor coordination
- Maintenance storeroom management — layout, receiving, issuing, cycle counting, min/max
- Contractor management — scope, safety, supervision, quality verification, invoice reconciliation
Reliability KPIs & Data-Driven Decisions
- KPI framework design — leading and lagging indicators aligned to reliability maturity
- Equipment metrics — OEE, MTBF, MTTR, failure frequency, availability by asset class
- Maintenance process metrics — PM compliance / effectiveness, schedule compliance, wrench time
- Cost metrics — maintenance cost per RAV, per unit of production, by work type and asset class
- Work management metrics — backlog age, completion rate, reactive vs. planned work percentage
- Inventory metrics — stockout frequency, inventory turns, dead stock, service level
- Reliability analytics — Pareto / bad-actor analysis, trending, Weibull, cost-of-unreliability
- Data governance and role-based dashboard / reporting design
Root Cause Analysis & Continuous Improvement
- RCA program development — trigger criteria, methodology, action tracking, effectiveness verification
- RCA facilitation — 5-Why, fishbone / Ishikawa, fault tree analysis, barrier analysis
- Bad actor identification and elimination — chronic failures, repeat work orders, high-cost assets
- Defect elimination — removing the sources of failure, not just managing consequences
- Reliability improvement project identification, justification, and tracking
- Benchmarking — internal trending, industry comparison, maturity model progression
Capital Planning & Asset Lifecycle
- Equipment condition assessments and remaining-useful-life estimation
- Capital expenditure planning and project justification (CER development)
- Repair-versus-replace analysis with lifecycle cost modeling — TCO, NPV, IRR
- OEM assessment coordination and vendor evaluation
- Shutdown / turnaround maintenance planning and execution
- Commissioning and acceptance testing for new or rebuilt equipment
- Asset lifecycle strategy — design, procure, install, operate, maintain, refurbish, replace, dispose
Pillar 03
Manufacturing Intelligence
Connect the floor to the front office — sensors, integration, and dashboards that turn real-time OEE, downtime, and throughput into decisions.
Build-out work in this pillar — infrastructure, dashboards, integration, and alerting — is an optional add-on, scoped separately from consulting engagements. Analysis with Quinn is included in every engagement.
Data Infrastructure & Connectivity
- Manufacturing data infrastructure assessment
- Sensor & PLC data integration
- Edge device selection & deployment
- Industrial IoT (IIoT) hardware design & installation
- Data historian setup & configuration
- Floor-to-dashboard system design
Dashboards & Visualization
- Live production dashboard design & deployment
- KPI dashboard development & implementation
- Custom manufacturing KPI framework development
- Data visualization & reporting tool selection
- Operator interface & HMI dashboard design
OEE, Downtime & Loss
- OEE data collection & reporting program
- Downtime tracking & loss analysis system
- Throughput & yield monitoring system
Systems Integration
- CMMS data integration & automation
- ERP / MES integration support
- Digital work order & maintenance integration
Alerting & Reporting Automation
- Real-time alerting & notification system
- Production reporting automation
Strategy & Roadmap
- Connected factory roadmap & strategy
- Digital-maturity assessment and phased build plan
- Technology selection aligned to the problems that matter
How the Pillars Work Together
Independent by design. Powerful in combination.
Each pillar stands on its own — but plant performance is interconnected, and most engagements span more than one.
Startups
Need Reliability infrastructure and Operations readiness — with Manufacturing Intelligence wired in from day one.
Turnarounds
Missed performance usually traces to underlying Reliability and Operations gaps. We fix the cause, not just the symptom.
Operational Assessments
A Pillar 1 assessment surfaces deficiencies across every other pillar — which makes it the natural entry point for a new relationship.
Ongoing Support
Sustained reliability and operations support keeps systems healthy long after the initial project is complete.
Let's Talk
Which capability do you need first?
Tell us your situation — startup, turnaround, or a specific gap — and we'll scope the right engagement.