Reading Time: 5 Min
Note: This is a fictional company
Recover The Output Your Line Is Already Losing
In the next 5 minutes you will find out how manufacturing plants like yours turn chronic line losses into verified recoveries and what it takes to get it done.
Why Do Line Losses Survive Good Engineering?
Every plant knows where it leaks. The losses hide in changeovers, micro-stoppages, and rework, they compound every month they run, and most plants answer the only way the budget process knows how: with more firefighting.
But really, it's a constraint problem disguised as a maintenance problem. The losses cluster at one constraint, and activity aimed anywhere else leaves them untouched. Most plants get stuck when:
1
They add maintenance
Preventive schedules tighten and spend rises, but the stoppages move elsewhere on the line, because the constraint was never mechanical.
2
They add dashboards
A monitoring layer reports the losses in higher resolution. Reporting the constraint and removing it are different disciplines.
3
They call one big integrator
A full-line retrofit quote arrives at seven figures, the board defers it, and the constraint keeps charging rent while everyone waits for a budget year.
A Constraint Problem Needs a Constraint Solution
So instead of more firefighting, we work the root cause: find the one constraint, engineer the fix for it alone, and verify the recovery on the line.That discipline runs as a four-stage sequence, each stage with a decision gate, and you can stop at any gate while keeping whatever is produced by that point.
1
Loss audit
Two weeks on site. We instrument the line and rank every loss by annual cost.
2
Constraint design
Engineering the fix for the top constraint only. One drawing set, one number, one payback period.
3
Implementation
Our engineers deliver with your team, on running lines, without a shutdown window.
4
Verification
Thirty days of measured output against baseline. The invoice references the measurement.
Wherever you stop, you leave with something you can act on without us. After the audit you know which loss costs you most and what fixing it takes. After the design you're left with a build-ready drawing set with its payback period. After verification you have thirty days of measured proof the fix paid for itself.
Client Results
Three recent projects, measured on running lines. In each case, the final invoice cited the verified result, and the client's words below are theirs.
€2.4M
Recovered output · Year one
"They found the constraint in nine days. Our own team had circled it for two years. The verification period removed every argument the board had."
JK
J. Kowalski · Operations Director
Beverage packaging · Poland
11 days
Changeover cut from 31 · Verified
"The retrofit paid for itself before the verification window closed. First supplier I have worked with who invoiced against a measurement."
RS
R. Sandberg · Plant Manager
Automotive components · Sweden
+14%
OEE on Line 2 · Verified
"We stopped after the audit the first time, honestly. Came back eight months later and ran the full sequence. The gates are real, nobody pressured us, and the payback landed inside the quarter."
MV
M. de Vries · Technical Director
Food processing · Netherlands
What Working Together Looks Like
Below is a short summary of what you can expect:
| ENTRY POINT | We start with the loss audit. In 2 weeks you get a ranked loss register with engineering recommendations. Yours to keep regardless of what follows. |
| TIMELINE | After the audit is complete, it takes us 3 weeks to complete the constraint design. Implementation typically complete inside one quarter. |
| YOUR COMMITMENT | To be effective, we need from you: an operations owner in a weekly 30-minute review, site access for two engineers, and baseline data before we arrive. |
| INVESTMENT | From €18,000 for the loss audit. If you continue, implementation is quoted as a fixed price next to the loss it removes, so you see cost against annual saving before you commit. |
But Working With Meridian Isn't for Every Plant
We're built to work with small to medium sized plants as follows:
A FIT IF:
[+] You run a plant with 50 to 500 people and your lines lose output you can see: long changeovers, stoppages, rework
[+] Those losses are worth real money to you, at least €40,000 a year
[+] The person who owns this problem, usually the operations director, will be on the calls with us
[+] You want this fixed within the next six months, not some day
PROBABLY NOT A FIT:
[x] You already know what to build and just need extra drafting or wiring hands
[x] The person who controls the budget won't talk to us until it's time to sign
[x] You already have a supplier you intend to keep, and you need our quote to negotiate their price down
A Note on Timing
Line losses compound quietly. Across our audits, a site losing one shift a week to stoppages and changeovers leaves €12,000 to €40,000 on the floor every month. Waiting for the perfect budget year means paying that invoice while you wait, which usually amounts to millions.
If you are a fit after our initial screening, we'll let you know that the audit makes sense. If we're not, we'll alos tell you.
Roughly 25% of the plants we speak with aren't a fit, and we tell them. Of the rest, most book the audit within the week, because the math is in front of them and every month of delay has a price on it.
Roughly 20% wait and delay a decision.
A site losing one shift a week to stoppages and changeovers leaves €12,000 to €40,000 on the floor every month. That number doesn't pause while you think about it. Waiting two quarters for a cleaner budget year costs more than the audit and usually more than the fix.
Our Promise
If the loss audit fails to identify recoverable losses in the next 3 months worth at least five times its fee, we refund the audit.
And implementation is invoiced against the thirty-day verification measurement – so you never have to decide if the project worked, the numbers will decide for you. We can make this promise because the audit finds what is already there, and our implementation work is only paid out of your gains.
Let's Check If The Audit Makes Sense
You'll spend 30 minutes with a principal engineer. Before the call we'll prepare a preliminary read of your situation, so you leave with something useful even if we go no further.
"The verification period removed every argument the board had."
J. Kowalski · Operations Director, beverage packaging
Document
How We Work • Company Intro
Issued By
Meridian Controls Ltd
Revision Date
July 2026