Why have a Plant Assessment?

In recent years, the majority of manufacturing facilities in the US have gone through major downsizing and, even today, are trying to do more with less. The question becomes, how can we quickly and economocally become much more profitable? Sizeable gains in profitability in the near term can translate to significant additional monies for planned growth and expansion.

PJ Associates is uniquely qualified to assist in this process with more than 18 years dealing directly with a wide variety of roll goods manufacturers and converters. We have improved plant yields, reduced scrap and improved outgoing quality. This experience has resulted in significant knowledge across a number of industries such as papers, textiles, labels, tapes, nonwovens, etc., and with numerous roll goods related processes such as lamination, coating, slitting bag & pouch manufacturing.

What are the components of a Plant Assessment?

A plant assessment consists of a 2 to 3 day on-site visit dependent on plant size and complexity. The average visit is 2 ½ days. The visit is followed up with a written report that ranges between 10 – 25 pages. This report discusses the significant observations and findings that were generated by the on-site visit and includes very specific suggestions and recommendations. Total time spent by PJ Associates on a plant assessment averages 5 – 6 days.

The objectives of a plant assessment usually revolve around the strategies and internal programs required to significantly and quickly improve overall plant yields and product quality while greatly reducing scrap and downtime. The time period for the implementation of these recommendations usually ranges from three months to a year. Expected overall ROI is typically six months or less.

Short term recommendations in the report will usually result in the plant assessment paying for itself; while longer term recommendations are aimed at breakthrough gains in the areas above.

Should a company wish to use this service, a three page assessment breakdown will be e-mailed at least two weeks in advance of the visit. Additional items may be added during the visit dependent on the information gathered at that time.

A summary meeting will be held at the end of the visit to cover both visit findings and follow-up informational needs.

An interim report will be issued within one week of the visit and a final report will be issued usually within two weeks of the visit end.