OSCAR
The tool behind every assessment.
OSCAR stands for Operations Scan, Cost Analysis & Recommendations. We use it in every assessment to bring your data together, look at each area of your operation the same thorough way, and rank what we find by dollar value. It's how your assessment is built on numbers, not just opinions.
Free 30-minute call, no obligation
How it works
Scan, analyze, recommend.
Scan
We bring in what you already have, like ERP exports, spreadsheets, and logs, plus what we see and capture during our time at your facility.
Analyze
Each area of the operation has its own analyzer, built to spot the patterns that quietly cost manufacturers money, like reorder points that no longer match demand or the same downtime cause repeating every week.
Recommend
Every opportunity gets a dollar value, a root cause, and a place in a ranked plan, so you know what to fix first and what it's worth.
Inside OSCAR
Ten areas where manufacturers lose money.
OSCAR (Operations Scan, Cost Analysis & Recommendations) is built from ten analyzers, one for each area of a manufacturing operation. Each analyzer is a set of checks designed for that area: the data to pull, the patterns to look for, and how to put a dollar value on what it finds.
Pick an area to see what we look at. A Single Area or Multi-Area Assessment covers the areas you choose; a Full Operations Scan covers all ten.
Inventory
Analyzed with IVY (Inventory Value & Yield)
How much cash is tied up in the wrong stock, and why do the right parts run short?
What it looks at
Stock levels, usage, reorder points, safety stock, lead times, and count accuracy
Data it uses
Item master, inventory balances, transaction history, purchase orders
What it flags
- Excess and slow-moving stock
- Reorder points that don't match usage
- Frequent shortages and expedites
Scheduling and capacity
Analyzed with CAL (Capacity & Attainment Lens)
Why do ship dates slip, and how much can you really make?
What it looks at
Planned versus actual production, capacity by machine and shift, setups, and schedule changes
Data it uses
Work orders, routings, production history, shift calendars
What it flags
- Bottlenecks that set the pace
- Schedules that assume capacity that isn't there
- Frequent reshuffles and late orders
Equipment and downtime
Analyzed with MAC (Machine Availability & Capacity)
Why do machines stop, and which stops cost the most?
What it looks at
Downtime by machine and reason, short stops, changeovers, and availability
Data it uses
Downtime logs, production counts, machine data where available
What it flags
- Stop causes that repeat
- Changeovers over target
- Short stops nobody records
Quality and scrap
Analyzed with ROSE (Rework, Output & Scrap Evaluator)
Where do scrap and rework come from, and why do they repeat?
What it looks at
Scrap and rework by part, process, and machine, where defects are found, and corrective actions
Data it uses
Scrap logs, inspection records, nonconformance reports, returns
What it flags
- Repeat defects
- Defects caught too late
- Corrective actions left open
Labor
Analyzed with WES (Workforce Efficiency Scan)
Where does your team's time go, and what's behind the overtime?
What it looks at
Hours against output by job, line, and shift, overtime, and time lost to waiting or searching
Data it uses
Timekeeping, labor reporting, production output
What it flags
- What drives overtime
- Unbalanced workloads
- Outdated job standards
Material flow and lead time
Analyzed with FLO (Flow & Lead-time Observer)
Where does work wait, and how long does an order really take?
What it looks at
Where work waits, time between steps, and total lead time per order
Data it uses
Order and work order dates, routings, work in process
What it flags
- Long queues between steps
- Lead times far longer than the work itself
- Batching that slows flow
Maintenance
Analyzed with MAX (Maintenance & Asset eXaminer)
Is maintenance planned or mostly reactive, and what does that cost?
What it looks at
Planned versus reactive work, backlog, response times, and repeat failures
Data it uses
Maintenance work orders, preventive maintenance schedules, downtime logs
What it flags
- Too much reactive work
- Overdue preventive maintenance
- The same asset failing again and again
Purchasing and suppliers
Analyzed with PAM (Purchasing Analysis & Metrics)
Are late or costly suppliers hurting your schedule and margins?
What it looks at
Supplier on-time delivery, lead time reliability, price changes, and expediting
Data it uses
Purchase orders, receipts, supplier records
What it flags
- Late suppliers hurting the schedule
- Lead times that don't match planning settings
- Premium freight
Demand and delivery
Analyzed with FRED (Forecast, Requests, Execution & Delivery)
How well do you plan for what customers will order and when?
What it looks at
Forecast against actual demand, order patterns, and on-time delivery to customers
Data it uses
Sales orders, shipments, forecasts
What it flags
- Forecasts that keep missing
- Promise dates not tied to capacity
- Seasonal swings nobody plans for
Systems and data
Analyzed with IDA (Integration & Data Audit)
Can you trust your numbers, and are old systems holding you back?
What it looks at
How systems connect, duplicate entry, data accuracy, and legacy software risk
Data it uses
System list, sample reports, interviews
What it flags
- Retyping between systems
- Numbers that disagree
- Unsupported legacy software
The result
A report with a number on every finding.
OSCAR’s output becomes your assessment report: opportunities ranked by annual value, the root cause behind each one, quick wins you can act on right away, and a phased plan with expected payback.
Why it works
OSCAR doesn't replace people who know manufacturing.
Our team runs every assessment: walking the process, talking with the people who do the work, and judging what matters. OSCAR makes sure nothing gets missed, every area is looked at the same thorough way, and every finding comes with a number you can act on.
Common questions
Questions about OSCAR
Do we have to install anything?
No. We work from exports of the data you already have and what we capture on site. Tracking tools are only added if you choose the Data Capture add-on.
What data does OSCAR need?
Usually standard exports from your ERP and the spreadsheets or logs your team already keeps. If some of it is missing or messy, that's normal, and part of what the assessment shows.
Is our information kept private?
Yes. Your data is used only for your assessment, and we're happy to sign an NDA before we start.
Do we get to keep the results?
Yes. The report and everything in it is yours, whether or not we build anything together.
Get started
See what OSCAR finds in your operation.
Book a short call. We'll talk through what you're seeing and recommend which analyzers to start with.