The business case
The two-minute version, for whoever signs the check.
Denim Sewing 2 is 10.2 points under a 75.0% plan over the last 30 days. Every figure below is the same one Tánger's own dashboard prints — nothing here is rounded up to make the case.
Denim Sewing 2 · Tánger · last 30 days
Loss found and priced
$164,605
Priced at the contribution margin this line earns per hour — not a generic rate card.
$15,500 of it is upstream starvation — the fix is not a mechanic on this line.
Not all of it is this line's fault, and not all of it is expensive to fix.
The Pareto ranks every category by money; Fix first ranks the same five by what it actually takes to move them. The two lists do not agree with each other, and that disagreement is the finding — the biggest number and the cheapest fix are rarely the same row.
- 1Minor Stops$67,695 · 41%
Hatched: $15,500 the line sat starved, not broken — upstream supply.
- 2Breakdowns$41,220 · 25%
- 3Setup & Changeover$22,110 · 13%
- 4Production Rejects$21,400 · 13%
- 5Startup Rejects$12,180 · 7%
Top three categories carry 79.6% of the money.
- 1Minor Stops is the biggest loss$67,695needs investigation
503 of those minutes were the line sitting starved rather than broken — $15,500 of it. That share is upstream supply, not maintenance.
- 2Changeovers run 10 minutes long$22,110fast / low-cost fix
34 minutes against a 24 minute baseline across 40 events. Changeover practice is the lever here, and it is this line's own work.
Of the five, only one is marked fast / low-cost fix: changeovers run 10 minutes long, worth $22,110 every 30 days — no capital request, because the practice is this line's own to change.
One export is enough to see whether any of this is true for discrete manufacturers running shift-based lines like yours.
14 days, one line, no card.