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The full capability set.

A detailed look at what we do across all five 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

Quality & Food Safety

Protect your consumers, your brand, and your license to operate — with systems that work on the floor, not just on paper.

Quality Management System (QMS)

  • QMS design and implementation — policies, procedures, work instructions, records
  • Document control — creation, revision, approval, distribution, retention
  • Nonconforming product and material procedures — identification, segregation, disposition
  • Customer complaint management — intake, investigation, CAPA, trending
  • Corrective and preventive action (CAPA) program development
  • Internal audit program design — schedules, checklists, auditor qualification, reporting
  • Management review program — agenda, inputs, outputs, action tracking

Process Quality & Control

  • Statistical process control (SPC) — control charts, capability studies
  • Incoming material inspection and raw material specification programs
  • In-process quality checks and hold-and-release procedures
  • Finished product inspection, testing, and release protocols
  • Sampling plans — frequency, methodology, acceptance criteria
  • Measurement system analysis and instrument calibration programs

Supplier Quality & Food Safety

  • Approved supplier program development — qualification, evaluation, monitoring
  • Supplier audit programs and scorecards
  • Raw material and packaging specifications — micro, chemical, physical, allergen requirements
  • Certificate of analysis (COA) and letter of guarantee management and verification
  • Receiving inspection and acceptance criteria
  • Foreign Supplier Verification Program (FSVP) compliance

HACCP & Preventive Controls

  • HACCP plan development and validation — hazard analysis, CCPs, critical limits, monitoring, verification, recordkeeping (21 CFR Part 120, Codex)
  • Preventive Controls for Human Food (PCHF) under FSMA — process, allergen, sanitation, supply-chain controls, recall plans
  • Food safety plan reassessment and revalidation — annual and trigger-based
  • Process authority coordination — thermal processing, acidification, aseptic operations

Prerequisite Programs

  • Sanitation programs — master sanitation schedules, SSOPs, chemical management, verification and validation
  • Environmental monitoring (EMP) — pathogen / indicator sampling, zoning, corrective actions, trending
  • Allergen management — cross-contact risk, segregation, labeling, cleaning validation, rework controls
  • Foreign material control — glass and brittle plastic, metal detection, X-ray, screens and filters
  • Pest management — IPM, contractor oversight, trend analysis
  • Water safety and potability programs
  • Personal hygiene and GMP programs — training, monitoring, enforcement

Regulatory Compliance

  • FDA FSMA compliance — Preventive Controls, Produce Safety, FSVP, Intentional Adulteration
  • FDA inspection readiness and 483 response support
  • State and local regulatory requirements — permits, licenses, inspections
  • Labeling compliance — nutrition facts, allergen declarations, regulatory claims
  • Product and facility registration requirements
  • Export certifications and international regulatory requirements
  • Recall program development — mock recalls, team training, communication plans

Training & Culture

  • GMP training — new hire orientation, annual refresher, role-specific
  • HACCP awareness and HACCP team training
  • Allergen awareness training
  • Sanitation and hygiene training
  • Quality awareness and inspection technique training
  • Culture of food safety and quality assessments and improvement initiatives

Continuous Improvement

  • Quality and food safety KPI development and trending — reject rates, complaints, audit scores, cost of quality, EMP results
  • RCA training and facilitation for quality and food safety events
  • Process improvement projects — waste reduction, yield improvement, defect elimination
  • Hold and release, recall readiness, and crisis management support
Pillar 04

SQF & GFSI Certification

Get certified. Stay certified. Recover from setbacks. We handle the full audit lifecycle.

SQF Certification Readiness

  • SQF Code Edition 9/10 gap assessments — Module 2 (Fundamentals), Module 11 (Food Manufacturing), and others as applicable
  • Non-conformance classification — Major, Minor, Critical — with prioritized action plans
  • SQF system development — food safety fundamentals, food safety plans, quality plans
  • SQF Practitioner designation support — role definition, training, competency verification
  • Document system architecture — policies, procedures, work instructions, forms, records, specifications
  • Pre-audit readiness verification and mock audits
  • Certification body selection and audit scheduling coordination

Other GFSI Scheme Support

  • BRC Global Standards — gap assessment, program development, audit preparation
  • FSSC 22000 — ISO 22000 foundation, sector-specific PRPs, additional requirements
  • Scheme comparison and selection guidance — choosing the right GFSI scheme for your market and customers

Audit Lifecycle Management

  • Initial certification preparation — first-time audit readiness
  • Surveillance audit preparation — maintaining compliance between certification cycles
  • Recertification audit preparation — code edition changes, scope changes, program evolution
  • Unannounced audit readiness — sustaining audit-ready status year-round
  • Multi-site and multi-scope coordination

Audit Recovery & Remediation

  • Failed audit response — root cause analysis, CAPA development, timeline management
  • Critical non-conformance remediation and re-audit preparation
  • Regulatory warning letter and consent decree response support related to third-party findings
  • Customer audit failure recovery — addressing customer-specific requirements beyond GFSI
  • Systemic non-conformance diagnosis — documentation gaps vs. implementation gaps vs. cultural gaps

Internal Audit & Management Review

  • Internal audit program development — schedules, checklists, auditor competency, reporting per SQF/GFSI codes
  • Internal auditor training and qualification
  • Management review facilitation — structure, inputs, outputs, action tracking
  • Continuous improvement programs — trending, KPI development, corrective action effectiveness verification
  • Outsourced internal auditor services on a recurring basis

Not sure which scheme or where to start?

Most facilities begin with a gap assessment against the code they're accountable to. We'll tell you exactly where you stand and what it takes to pass.

Book a gap assessment
Pillar 05

Manufacturing Intelligence

Connect the floor to the front office — sensors, integration, and dashboards that turn real-time OEE, downtime, and throughput into decisions.

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, Operations readiness, Quality & Food Safety programs, and SQF certification — all five pillars working together from day one.

Turnarounds

Audit failures usually trace to underlying Reliability and Operations gaps driving the Quality and Food Safety symptoms. We fix the cause, not just the finding.

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 SQF and Quality support keeps systems healthy and audit-ready long after the initial project is complete.

Let's Talk

Which capability do you need first?

Tell us your situation — startup, turnaround, certification, or a specific gap — and we'll scope the right engagement.

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