Can your plant see itself?
The Plant Score grades a facility on four pillars — See it, Trace it, Adopt it, Retain it — from a half-day walkthrough plus one measured 30-day sprint. One number, twelve components, and a rubric an engineer can audit.
Everyone in the room has a number for how the line is running. No two of them match, and none of them came from the machine.
You cannot improve what the plant cannot see. The Plant Score measures the seeing first — then prices what the blindness costs.
The four pillars
Twelve components underneath them, each scored against a written rubric — graded questions, timed exercises, evidence pulled on the floor.
See it.
Does the plant have a live picture of what is running, what is down, and why? Sensors, dashboards, and whether anyone actually looks at them during the shift.
Trace it.
Can you follow a part, a batch, or a fault backwards through the process? Genealogy, scrap attribution, and how long it takes to answer a customer's 'which lot was this'.
Adopt it.
The tooling exists — is it used? Adoption is scored on the floor, at the shift, by the people whose hands are on it. Shelfware scores zero no matter what it cost.
Retain it.
Does the improvement survive the person who made it? Standard work, handover, and whether last quarter's fix is still in place this quarter.
The mirror moment.
Before the sprint, the room writes down what it believes. After thirty days of measurement, the two are put side by side. That gap is usually the most valuable page in the report.
The cost sheet.
The same walkthrough times what the hand-built weekly report actually costs in engineer-hours, at your loaded rate. Five cost lines, each tagged by how it is known. The case for fixing it prices itself.
Every number says how it is known
A score you can argue with is worth more than one you have to trust. When the intake said "we track everything" and the floor said otherwise, the floor won.
Pulled from the machine, the MES, or a timed observation on the floor.
Scored against a written rubric by someone who walked the line.
What the plant believes. Recorded, and marked as belief.
Nobody knows. Counted as a gap, not quietly rounded up.
Three people wrote down what they believed Line 4 ran at: about 80.
Thirty days of machine data said 54.
The score can only go up by measuring — never by hiding a bad number. That is the whole design.
What you get
An engagement, not a subscription: a half-day facilitated walkthrough, one measured 30-day sprint, and the report the plant argues with.
Priced once we've seen yours
Plant Score is set up and run for you, month to month. What it costs turns on how many lines you meter and how much of the data already exists — so we quote it once, on a call, against your actual situation.
Talk to Blue Star about the Plant Score
Tell us a little about your business and a person replies from hello@bluestarlogic.com — usually within one business day.