Find where manufacturing margin and cash are being lost.
Aigenrix identifies, quantifies and prioritises economic leakage in scrap, downtime, inventory and pricing before any implementation begins.
30 minutes, free and without obligation. The purpose is to assess whether a Profit Recovery Sprint is justified.
Manufacturing leakage mapped to the four categories we quantify
These are possible diagnostic areas, not guaranteed losses — the Sprint establishes which ones are material in your business. Each issue is listed once, under the category where the money is lost: bottlenecks and downtime are operational causes, and the sales they cost appear once, as lost throughput.
Margin leakage
- →Scrap and rework
- →Purchase-price variance
- →Overtime absorbed into unit cost
- →Pricing leakage
- →Margin erosion by SKU or customer
Working-capital inefficiency
- →Excess and obsolete inventory
- →High work-in-progress
- →Slow-moving stock
- →Receivables tied to delivery performance
Revenue leakage
- →Lost throughput — sales missed when output falls short of demand
- →Delivery failures
- →Stockout-driven missed sales
Operational inefficiency
- →Unplanned downtime
- →Low asset utilisation
- →Inefficient changeovers
- →Poor production scheduling
- →Throughput constraints (bottlenecks)
How each leakage type is actually detected
Scrap and yield loss
- →Production output vs. material consumption
- →Standard yield vs. actual yield
- →Scrap by line, SKU and shift
- →Trend and variance analysis over time
Downtime and utilisation
- →Planned vs. actual run time
- →Availability, performance and quality decomposition
- →Downtime reason-code frequency
- →Comparison across shifts and lines
Purchase-price variance
- →Standard cost vs. actual PO price by SKU and supplier
- →Price trend by supplier over time
- →Variance concentration by category
Working capital in inventory
- →Inventory days by SKU category
- →Slow-moving and obsolete stock ageing
- →Work-in-progress vs. throughput ratio
Data inputs, not software integrations
- →ERP transactions
- →Production and output data
- →BOM and routing data
- →Inventory records
- →Purchasing data
- →Labour and shift data
- →Downtime logs
- →Sales and margin data
These are data inputs the Sprint works from, read from the systems you already run — not new integrations or instrumentation.
We trace symptoms back to their operational cause
High overtime→unstable production planning→poor shift allocation→rush orders→margin leakage
Frequent changeovers→inefficient scheduling→small-batch production→higher unit cost→margin erosion by SKU
Poor inventory visibility→safety-stock overbuilding→excess inventory→cash trapped in working capital
Inconsistent supplier onboarding→uncontrolled purchase-price variance→margin leakage
What can happen once a leakage source is confirmed
Not every finding needs the same fix, and not every fix requires AI. The Sprint identifies which mechanism actually applies before recommending one.
How the financial effect is verified
Baseline → intervention → post-intervention measurement → realised financial effect
Identified leakage is an economic opportunity, not a guaranteed result. Realised effect is only confirmed once it is measured against the agreed baseline after implementation.
How the Sprint works for a manufacturing business
The same Aigenrix methodology applied to your production and cost data — not a different product for manufacturing.
Establish the baseline
Current financial and operational performance — pulled from the systems you already run, not a client questionnaire. The reference point every later number is measured against.
Identify economic problems
Locate the economically material losses or inefficiencies in margin, cash, revenue and operations — not a generic checklist, the ones your data actually shows.
Trace the underlying causes
Separate what the data directly shows from what still needs validation — observed facts, causal hypotheses, and evidence-supported causes.
Quantify recoverable value
Separate total economic exposure from the addressable portion management can influence, and from the value that evidence and feasibility indicate may realistically be captured.
Build the recovery case
Define the intervention, implementation cost, expected benefit range, payback, confidence level and validation KPI — the investment case a funding decision can actually be made on.
Is this a good fit for your business?
- →Approximately 20–250 employees
- →Approximately €3M–€50M annual revenue
- →Multiple lines, shifts or plants
- →Usable ERP, production or inventory data
- →Management wants measurable economics, not just a diagnosis
- →The business can act on findings once they are confirmed
Especially relevant when
- →Scrap, rework or overtime feels persistently high
- →Margin varies significantly by SKU or customer without a clear reason
- →Inventory keeps growing faster than sales
- →Downtime is tracked informally, if at all
See the methodology before you commit
No manufacturing case study is published yet, and we will not invent one. Review the methodology and the illustrative Sample Recovery Analysis used across every Aigenrix engagement.
Find out what manufacturing leakage is costing you
A Profit Recovery Sprint quantifies the exposure, prioritises what is worth fixing, and builds the investment case — before any implementation commitment.
30 minutes, free and without obligation. The purpose is to assess whether a Profit Recovery Sprint is justified.
Prefer email? team@aigenrix.com