KMS Operational X-Ray
Where is your EBITDA going?
A one-week executive diagnostic that identifies where profitability, capacity, productivity, and organizational effectiveness are being lost in your operation, and puts an estimated dollar value on each one.
See if Your Operation Qualifies
Three days onsite. Written report in five business days.
The Problem with Your List
Most manufacturing leaders can name three things that need fixing.
- Overtime that never quite comes down
- Scrap that gets solved and then comes back
- A line that runs beautifully one week and not the next
The list is not the problem. The problem is that nobody can say with confidence which item on it is costing the most, or which one will pay back fastest once it is addressed.
Internal teams struggle with this for understandable reasons. You are close to the operation, busy running it, and invested in the decisions that built it. Everyone in the room has a theory, and every theory is defensible.
What the KMS Operational X-Ray Delivers
An independent outside view of your operation, delivered in one week.
Through executive interviews, facility observation, and operational analysis, leadership gains clarity on where EBITDA is being lost, what deserves immediate attention, and where resources should be focused first.
At the conclusion of the engagement, leadership receives an EBITDA Opportunity Assessment Report containing:
- Prioritized findings
- Estimated financial impact
- Practical 90-day roadmap for action
Is the X-Ray the Right Fit For You?
The KMS Operational X-Ray is built for manufacturing organizations where improvement opportunities typically exceed $500,000 in annual EBITDA impact. Most fit a revenue range of $20M to $300M.
It is usually the right time when leadership is dealing with one or more of the following:
- Margin pressure
- Excessive overtime
- Quality concerns
- Delivery issues
- Equipment reliability
- Leadership frustration
How it Works
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Phase 1 | Executive Discovery: A virtual intake session to establish context, priorities, and what leadership already suspects.
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Phase 2 | Onsite Assessment: Three days on site. Gemba walks, executive and leadership interviews, and review of operational metrics and performance data.
- Phase 3 | Opportunity Prioritization: Every identified opportunity is ranked against four criteria: estimated EBITDA impact, ease of implementation, time to results, and organizational readiness.
- Phase 4 | Executive Readout: A debrief delivered at the conclusion of the onsite visit, so leadership has directional clarity before the written report is finalized.
- Phase 5. EBITDA Opportunity Assessment Report: Delivered within five business days of the site visit.
What Gets Examined
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Leadership Systems
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Strategic alignment, accountability, performance management, and communication effectiveness.
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- Production Operations
- Throughput constraints, flow interruptions, changeovers, and scheduling effectiveness.
- Quality Systems
- Scrap, rework, inspection burden, and customer complaints.
- Maintenance and Reliability
- Downtime drivers, preventive maintenance effectiveness, and equipment reliability.
- Supply Chain and Inventory
- Material availability, inventory levels, expedites, and supplier performance.
- Workforce Capability
- Overtime drivers, knowledge concentration, and problem-solving capability.
The Report
Six structured sections, delivered within five business days of the site visit.
- Executive Summary: Key findings, priorities, and recommendations.
- Operational Findings: Current state observations, strengths, risks, and constraints.
- EBITDA Impact Assessment: Estimated value ranges for identified opportunities.
- Opportunity Heat Map: Visual ranking by impact and implementation complexity.
- Prioritized Opportunity Portfolio: Recommended areas of focus for leadership consideration.
- 90 Day Action Roadmap: Suggested actions organized across days 1 to 30, 31 to 60, and 61 to 90.
Who Conducts the Assessment
Your Operational X-Ray is conducted by a KMS expert with more than 30 years of operational leadership and continuous improvement experience across manufacturing and process industries, including more than $165 million in documented operational impact over a ten-year engagement with a publicly traded minerals producer.
Credentials: Certified Management Consultant. MBA and chemical engineer. Lean Six Sigma Black Belt. Two U.S. patents in operational efficiency.
Sector experience: Chemical processing and mining. Building and medical products. Industrial manufacturing. Process industries.
Investment
$9,500 plus travel and lodging expenses.
The engagement is scoped for operations where identified opportunities typically exceed $500,000 in annual EBITDA impact. If the discovery conversation suggests the fit is not there, you will hear that before anything is committed.
What happens after the report
Four paths forward. The choice is entirely yours, and there is no obligation to engage KMS for any of them.
Option A. Internal execution: Execute the recommendations using your own resources and leadership.
Option B. Project support: Engage KMS for project facilitation and execution support on specific opportunities.
Option C. Guided program: Participate in the KMS 12 Week Guided Profit Acceleration Program.
Option D. Long term roadmap: Develop a longer-term operational excellence roadmap with KMS.
What the X-Ray is Not
The X-Ray is a rapid executive level assessment built to produce clarity, direction, and prioritization. It is not detailed process mapping, a Lean event, or implementation support.
We do all of that too. It is simply different work, and if that is what your operation actually needs, we would rather tell you on the first call and point you at the right program.
Find out where your EBITDA is going.
Start with a short conversation. We will confirm fit, walk through what the three days look like, and you will know whether this makes sense for your operation before anything is scheduled.