Factory Assessment
Factory assessment is the fact-based evaluation of organisation, technology, and business processes. The methodology combines on-site inspections, structured interviews, and data analysis to deliver a comprehensive view of maintenance maturity — identifying gaps, quantifying improvement potential, and grounding every recommendation in evidence.
This is not a compliance audit. It is a structured evaluation of how maintenance operations actually perform.
The assessment goes beyond standard conformity checks. Auditors spend several days on-site conducting facility walkthroughs, equipment inspections, and structured interviews across maintenance, production, finance, and IT — building an objective, evidence-based picture of current operational reality.
The outcome is a scored report with quantified improvement potentials across all assessed areas.
Findings are grounded in observed conditions and verified data — not self-reported surveys or generic benchmarks. Each of the 8 assessment areas receives an independent maturity score, with improvement opportunities prioritised by estimated financial and operational impact.
This provides the evidence base for informed investment decisions — whether the objective is building a transformation case, prioritising capital expenditure, or establishing a performance baseline across multiple sites.
We guarantee the outcome.
Other consultancies hand over estimates. We quantify concrete OEE improvement — in percentages and euros — and when delivered with Propelance, we commit to the result in writing.
We don't hand over slide decks. We take accountability.
Each area is evaluated independently based on on-site evidence — walkthroughs, inspections, interviews, documentation review, and data analysis.
The maintenance team's safety practices and how corporate policy is embedded in daily work: HSE training, KPIs, LOTO and work permits, chemical and environmental controls, and the orderliness of maintenance areas (5S).
The maintenance organisation examined along two dimensions: quantitative measures (team size, management layers, qualifications, employee satisfaction) and qualitative factors (team dynamics, motivation, level of engagement).
The concept and practice of measuring equipment effectiveness: OEE measurement systems, loss reporting, bottleneck analysis, root cause analysis (RCA) of failures, and support for continuous improvement teams and changeovers (SMED).
A review of the financial side of maintenance: cost structure, budget planning and control, approval processes, procurement and subcontractor selection, and spare-parts inventory management.
The maturity of preventive, corrective, condition-based (CBM), and predictive maintenance approaches: maintenance strategy, learning from failures and root cause analysis, and the use of Industry 4.0 tools on critical equipment.
An on-site inspection of the physical condition of equipment: availability of documentation, contamination and corrosion, life-extension measures (TPM), ease of condition checks, maintainability, and HSE considerations.
A comprehensive review of the organisation's digital maturity: digitalisation strategy and culture, the systems supporting the business and maintenance (CMMS, ERP, MES), cloud solutions, data-driven decision-making, and data and information security governance.
Planning ensures that work orders, parts, and resources are available in advance, while scheduling coordinates the different work types (preventive, corrective). The assessment also examines how the underlying CMMS supports these processes.
Defining the scope of the factory assessment with key stakeholders, naming the participants, and aligning across maintenance, production, and finance. Preliminary information gathering.
Gathering in-depth information about the maintenance function through facility walkthroughs, inspections, structured interviews, and documentation reviews.
Structuring the collected information into a unified picture of current performance — identifying strengths and the areas that offer the greatest improvement potential.
Presentation of a comprehensive assessment report covering the improvement opportunities and priorities identified — across all eight assessed areas.
Without a comprehensive, objective assessment, there's no way to know where to act first.
The Assessment delivers an independent picture across eight areas and ranks improvement opportunities by financial and operational impact. Facts instead of hunches; decisions instead of debate.
Request an Assessment
Contact us to discuss scope, timeline, and applicability to your operations.