Prototypes are easy.
Production is hard.

MOM powers production at scale.

Live in 5 days. One pilot line, however complex.

Fourem is Lean Manufacturing Operations Management Platform — for production, quality, maintenance, training, and parts.

The app your supervisor opens before the first part ships.

Production
Is the line running the way it's supposed to, right now?
Quality
Are we catching problems before they leave the station?
Maintenance
What's down, what's about to break?
Training
Who's covering, who's certified, who's new?
Parts
What's short, what's stuck, what's scrap?

One runbook. Every shift.

Win your shift.
Joe's Log
Production line is live in 5 days.
Then win the day.
KPI Widget
Kick off Continuous Improvement in 30 days.
Add it up — win the year.
ROI
Get 20x return on your assets.
Every shift, every line ›

All Five,
No Trade-Offs.

You already bought tools for this. Watch them still miss it.

Production
Quality
Maintenance
Training
Parts
What gets measured,
gets improved.
Three frameworks, one factory ›

MOM.
Built In.
Not Bolted On.

No KPI closes with one role. Different tools mean you align after the work. One tool means there's no after the fact.

1

How do you get more capacity out of the same floor?

Recovery

Today: the supervisor logs the call. The technician logs the fix. Two tools, two timestamps — MTTR isn't real until someone reconciles both.

Plant Manager
MTTR 0%

For plant managers who chose MOM

2

How do you lower the cost of running this floor?

Improve

Today: the supervisor flags it, the team fixes it in a meeting nobody's tool remembers. The fix doesn't stick — so it costs you again.

Plant Manager
MTBF 0%

For plant managers who chose MOM

3

Why does every rollout become its own production hell?

Change

Today: the engineer updates the SOP. The operator never sees it. The supervisor finds out at the next audit — too late to matter.

Plant Manager
Time to Market 0%

For plant managers who chose MOM

Problem solving.
Every shift. Every line.

Cost to deliver › ROI

Set up systems,
not goals.

McKinsey: 18 months to know if it worked. Most plant managers don't get 15.

Operational Impact
Per Shift
Line Efficiency
+0%
Factory Productivity
+0%
Time to Market
0%
18-Month Journey
Equipment Maintenance
Quality Inspections
Worker Training
Part Replenishment
CMMS
QMS
Kanban
LMS
CI
SOP
Dashboards
Spreadsheets
Data analytics
Radio
Messaging
Andon
Meetings
Plant Manager
30 days with Fourem
Drag up ↑
One Floor,
One App
P&L Impact
Estimated
Cost per shift
0%
$0
Recovered margin, this shift alone.
Joe's real shift — 5 days, not 18 months Watch →

Based on McKinsey's research: frontline coordination loss averages 1.8 hrs/day, and gains that hold for 18 months are far more likely to stick long-term. Directional math above, not a guarantee for your specific floor.

Now, the real questions.

The real questions ›

Go Ahead.
Ask.

Every plant manager has the same doubts. Here they are, answered.

How fast can this actually go live?

›

5 days. No IT integration, no infrastructure project — deployed between shift changes.

Do I have to rip out my CMMS, QMS, or LMS?

›

No other app is required.

What does it cost?

›

$22.95 per shift, per line. Less than what one bad shift already costs you.

Will my crew actually use it?

›

It's built to be opened once, at the start of a shift — not one more login nobody remembers. If it's not open, you'll know immediately, because nothing else is either.

We tried something like this before. It didn't stick.

›

Every role delivers impact inside the app — not after the fact.

Where does the data come from?

›

Nobody's watched. Everyone's just doing their job — the record happens on its own.

Every doubt, answered.
One decision left.

The Platform ›

Built For The Floor.
Used Every Shift.

Nothing on fire. Nothing to guess. Just the floor, running.

Set your targets
Run the shift
See how you're tracking
Fix what drifted
Desktop view
Mobile view
Desktop
Before a single unit runs — the plan is in the platform.

Target set. Method, material, people, and equipment — all linked before production starts.

Who it's for ›

Every Role.
Never Leaves The App.

The best manufacturing systems ever built ran on one idea: every defect comes from one of four places. Every role on this floor still maps to one of them.

VP / Operations Director
"I get a cost report seven days after the problem started."
‹ swipe for the fix ›
The VP who already knows before the meeting starts. Actual vs planned across every line, every shift — before anyone builds a report.
Plant Manager
"I know something is wrong. I can't tell which line or why."
‹ swipe for the fix ›
The plant manager who directs, not reacts. Bottlenecks ranked. Efficiency by station. Every open fix with a name on it.
Production Supervisor
"My shift target changes. My escalations go nowhere."
‹ swipe for the fix ›
The supervisor who runs the shift — not chases it. Target confirmed before the line starts. Every task assigned. Every escalation logged and owned.
Plant Controller
"Labor variance, scrap budget — I reconstruct all of it at month end."
‹ swipe for the fix ›
The controller who explains decisions, not variance. Cost per unit, per line, per shift — live. The books close without surprises.
Every production role.
"My role isn't listed above."
‹ swipe for the fix ›
Machine Operator · Line Lead · Shift Lead · Maintenance Tech · Quality Tech · Process Engineer · Safety Officer · Material Handler · Packaging Operator · Forklift Operator — and every role between them.
How it works ›

Live In One Day.
Proven By Day Five.

System live before the next shift. A dedicated industrial engineer with you through day five, until the line is proven — not just switched on.

Day 1
System live.
Shift log, quality plan, maintenance plan, and labor tracking configured and running before the next crew clocks in.
Day 2
Crew trained, first real shift logged.
The engineer trains the supervisor and operators on logging, live, during an actual shift. Not a canned video — real guidance, on a real shift.
Day 3
Gaps get caught, not guessed at.
The engineer reviews what the first two days of logs actually show — separating what's chronic from what's a one-off.
Day 4
Run at Rate.
The line runs a full Significant Production Run — normal tooling, normal crew, normal pace — to prove the plan holds under real conditions.
Day 5
Signed off. Handed over.
The engineer passes the line to your own team — a real Shift Handover, not a slide deck. Day six, it's running without them.
From the floor
The boardroom changes the goal. The floor never changes the levers.
Every mandate lands on the same four things — Man, Machine, Material, Method. The language changes every cycle. The floor doesn't.
Read the article →
4 min read · Operations Leadership
4 min read

The Boardroom Changes the Goal.
The Floor Never Changes the Levers.

The mandate arrives in a deck.

Sometimes it is cost reduction. Sometimes it is capacity release. Sometimes it is automation, reshoring, scaling, margin recovery, new product launch. The language changes every planning cycle. The urgency is always real.

The factory boss reads it. Nods. Goes back to the floor.

The floor has not changed.

Every mandate that has ever come down from a boardroom has landed on the same four things. Man. Machine. Material. Method.

That is it. There is no fifth lever. Cost reduction is a Man and Material problem dressed in finance language. Automation is a Machine and Method problem dressed in capital expenditure language. The mandate changes the emphasis. It does not change the floor.

The factory boss who understands this has a significant advantage. Every new goal is just a different mix across the same four levers. The diagnostic is always the same question: where are my 4M's today, where do they need to be for this mandate to land. The distance between those two answers is the project.


This is where most mandates fail.

The project manager arrives with a plan. Two M's are prioritized. Budget allocated. Timeline set. The other two M's were not in the plan. Man was not retrained for the new process. Material was not requalified for the new equipment tolerances. The automation project delivered on time. The floor did not move.

This is not a project management failure. It is a current state failure. Nobody knew precisely where all four M's were when the mandate arrived.


The factory boss who knows their 4M's — precisely, currently, across every line — does something different when the mandate arrives.

They don't start with the plan. They start with the gap.

All four. All the time. Mix will change. Nothing gets skipped.

Fourem is built on this framework. Not as a theory. As a live operating view. Every M has a current state visible at any moment. When a mandate arrives, the factory boss does not estimate the gap. They see it. Immediately. Across all four simultaneously.

When all four M's are planned and visible, any mandate is just a destination. The floor already knows the route.

3 min read

Why We Built This

Every month, and every quarter, leadership reviews a set of numbers that already happened — without any way to see which shift, which machine, or which decision actually caused them.

That number came from a loop: someone noticed a leak, wrote it down, sent it up, and somewhere later resource check decided which leak to deal with first and when second and so on — and only then did someone actually go fix it, the last step of the same loop, and usually the slowest one.

Our founder saw this loop everywhere, including at Tesla — a company with real budget and real pressure to move fast. Even there, no single tool existed that sped up the whole loop. Every other place worked the same way: three to five months just to buy a tool that solved one piece of it. Never the loop itself.

There is only one way to actually fix that: collapse the handoffs, don't manage them faster. That's the whole spec behind smart, smooth, fast — the best designed, most user-friendly, and most complete shift manager that ever existed. Every word in that sentence kills one specific handoff in the old chain:

Smart — kills the "decide what to attend first" step. In the old loop, someone had to look at a pile of captured data and figure out which leak mattered most, usually in a meeting, days later. Smart means the system already knows which leak is expensive the moment it happens — there's no separate decision step left to schedule.

Smooth — keeps "capture" from becoming its own bottleneck. The person capturing the leak is the same person standing at the machine when it happens. If logging it is clunky, they either log it late or don't log it at all — and you've quietly reintroduced the exact delay you built this to kill, just moved earlier in the chain.

Fast — is the direct measure of cash saved, not a feature. A leak caught in the same minute costs nothing. The same leak caught next week has already left the building. "Fast" isn't a quality of the tool — it's a direct read on how much money escaped before someone acted.

Best designed — kills the "report it up" step. Reporting exists because the right person can't see the floor directly. Good design means the right person is already looking at the actual event, live — there's nothing left to translate or forward.

Most user-friendly — protects the data at its source. This isn't for the plant manager's comfort. It's for the frontline worker who has to use this mid-shift, under pressure, every single time. If it's not built for them specifically, the input is wrong or late, and every downstream step — decide, act — inherits that lag from the very first moment.

Most complete — closes the last exit ramp back to the old loop. A leak can come from any of the four things a factory runs on — man, machine, material, method. If the system only watches two of them, the other two just quietly fall back into the old days-weeks-months loop, because nothing live is catching them. Complete means there's no category left where the old loop can still hide.

Win the shift. Win the day. Win the year.
Before shift. Mid shift. After shift. All covered.
At $22.95 per production log.
Plant Manager
Line Supervisor
Single App for your scale
Production Lines
2
Production Facilities
2
LINE CLEARANCE
FIRST ARTICLE
BOTTLENECK
DOWNTIME
PASSDOWN
SHIFT REPORT
APQP
PPAP
ANDON
RCA
DIGITAL THREAD
OPC UA
4 lines. Complexity. 1/5th the effort.
What's included in the package
  • ✓ App — iOS / Android / Web
  • ✓ Dedicated industrial engineer for your first 5 days
  • ✓ First 90 days included — unlimited lines, unlimited users
Security & Control ›

Your Floor.
Your Data.
Nobody Else's.

Access, control, and ownership — all in one place.

Role-based access
The VP sees every line. The supervisor sees their line only. Finance sees cost data. Access is defined by role, not by trust.
Every action timestamped
Who logged it. When. From where. Every shift entry, escalation, and corrective action has a full audit trail. Nothing anonymous. Nothing editable after the fact.
Your data stays yours
Your production data is not shared, sold, or used to train anything. Export it at any time in full. Delete it and it is gone.
Works on any device
Desktop in the office. Mobile on the floor. Same data, same access, same audit trail. Browser-based. No installations required.
Self-deployed. No vendor access.
Fourem runs in your environment. Nobody from Fourem can see your floor data, your shift logs, or your production numbers. You deploy it. You own it.
Uptime you can rely on
Production doesn't stop for maintenance windows. Fourem updates run off-hours. If something is down, you know before your shift starts.

Full security review, before you sign anything — not after.

The Cost Playbook ›

Five Costs.
One Plan Each.

Each playbook shows the planned cost, the actual cost, where the gap lives, and exactly what it takes to close it. Real numbers. Real product lines. No theory.

Playbook 01
Cost of Quality
FPY 99% planned → 85% actual
Explore →
Playbook 02
Cost of Downtime
$4,300 per unplanned hour. Not $1,200.
Explore →
Playbook 03
Cost of Labor
$9.30/unit hidden in headcount variance
Explore →
Playbook 04
Cost of Inventory
$415K/year invisible on the shop report
Explore →
Playbook 05
Cost of Compliance & Safety
One incident. The fine is the cheapest part.
Explore →
Cost of Quality — Playbook 01
Cost of Quality
Playbook · Cost Cut #1 of 5
Planned FPY
99%
What quality was designed for at launch
Actual FPY
85%
What you're running today
14% of production is scrap or rework. On 1,000 units/day at $50/unit — that's $7,000 a day bleeding with no output. Every decision to fix this is being made on data that is already 7 days old.
Problem
What each role is being asked — and what they actually know
If it was planned upfront
VP / Operations
Where is FPY today vs plan?
99%, on plan. Quality signed off before launch.
What's the cost impact if it drifts?
$X per point. Already factored into margin targets.
Production Manager
Which parts are most likely to fail?
Quality identified the 5 parts causing 80% of failures.
What's the recovery path when quality drops?
Defined. Escalation path, fix ownership, estimated time to restore.
Supervisor
When something fails, what's my first call?
Follow the plan. Log it. Call quality lead. Stop parts until cleared.
How do I know it's a drift and not normal?
Control limits are set. Anything outside triggers a report.
What's actually happening
VP / Operations
Where is FPY today vs plan?
85%. But the number is 7 days old. Might be worse.
What's the cost impact?
Not calculated. We'll see it at month-end close.
Production Manager
Which parts are failing?
Unknown. Need to pull data across all 224. Takes two days.
What's the root cause?
No standard. Each failure is a separate investigation.
Supervisor
When something fails, what's my first call?
I text around. Try to fix it on the line. Hope it holds.
Is this a drift or is it normal?
No baseline. Everything feels like firefighting.
What it costs to hold 99% FPY
Not aspirational. Each box below is real work with a real price. Business either staffs and executes this cycle — or finds a tool that runs it at a fraction of the overhead.
Plan
Before the line runs
  • Which parts drive 80% of failures?
  • Quality standard defined per critical part
  • FPY target agreed across VP, PM, Quality
  • Failure mode known before first unit
  • Cost impact per point of FPY drift
Do
On the floor, every shift
  • Quality checks run per defined standard
  • Every failure logged at the station
  • Escalation called when drift is found
  • Parts stopped until quality is cleared
  • Fixes executed per known failure mode
Check
Track drift from plan
  • FPY tracked daily — not weekly
  • Scrap and rework cost tallied per shift
  • MTTR and MTBF compared to plan
  • Which parts drifted and by how much?
Without structured Check: someone downloads raw data (3 hrs), builds a spreadsheet (4 hrs), presents it (2 hrs). Decision lands 7 days after the problem started. That labor is a cost too.
Act
Close the loop
  • Root cause identified per failure mode
  • Quality standard updated if assumptions broke
  • Fix applied and confirmed on next batch
  • FPY recovering toward plan — tracked
  • Cycle resets with updated baseline
Most businesses execute Plan well and Do inconsistently. Check is a manual report nobody trusts. Act never happens because Check was too late. Fourem's four studios are built on this cycle. Check becomes real-time. Act becomes the next shift's Plan. The loop closes — at 1/20th the reporting overhead.
Operations Room
Three businesses. Same gap. Different outcomes.
224-Piece BOM
Power Generator Assembly
Without plan$20K/month
With plan$4.2K/month
Annual savings$190K+
Read what happened
25+ Change Requests Active
Battery Module Production
Without plan220 hrs / change
With plan12 hrs / change
Annual hrs recovered5,200+ hrs
Read what happened
12 Field Failures / 1,000 Units
Swimming Pool Vacuum
Without plan$118K / recall
With plan$6K upfront
Brand damageAvoided
Read what happened
Cost of Downtime — Playbook 02
Cost of Downtime
Playbook · Cost Cut #2 of 5
Planned Uptime
95%
What the line was scheduled to run
Actual Uptime
76%
What actually ran this week
19 points of uptime lost. Most plants count only lost production. Here's what one unplanned hour actually costs — across all six layers.
Cost per unplanned hour down
Direct production loss $1,200 · Idle labor $1,000 · Recovery overtime $820 · Emergency parts & labor $400 · Customer penalties $600 · Restart scrap $280
Total per hour $4,300 — not $1,200. Every hour counts all six.
Problem
What each role is being asked — and what they actually know
If it was planned upfront
VP / Operations
What does one hour of downtime actually cost us?
$4,300 — production loss, idle labor, overtime, parts, penalties, restart scrap. All counted.
Which lines are at risk this quarter?
Line 3 and Line 7. PMs are scheduled. Spares are stocked for both.
Production Manager
Which equipment fails most and how long to fix?
Conveyor drive, Station 6 — MTBF 340 hrs, MTTR 1.5 hrs. Spare is on the shelf.
When a line stops, how fast do I know recovery time?
Within 10 minutes. Failure mode history tells maintenance the fastest fix.
Supervisor
When equipment stops, what's my first move?
Log the stop code. Call maintenance. Recovery path is posted at the station.
Is this a 10-minute fix or a 4-hour fix?
Stop code tells me. Each code has an expected MTTR. I know when to escalate.
What's actually happening
VP / Operations
What does one hour of downtime actually cost us?
We track lost production. The other five costs — nobody's adding those up.
What's the full cost impact this week?
Not calculated in real time. We'll see something at month-end close.
Production Manager
Which equipment is causing the most downtime?
Probably Station 6 again. Haven't pulled the stop logs this week.
When will maintenance have it fixed?
They're on it. No ETA. Depends what they find when they open it up.
Supervisor
When equipment stops, what do you do?
Radio maintenance. Wait. Try a restart. Wait more. Hope it holds.
How long has this been happening?
Feels like months. Nothing's being tracked so there's no pattern to show anyone.
What it costs to hold 95% uptime
Downtime is predictable — if you run this cycle. Every box below is real work with a real price. Business either executes this or keeps paying $4,300 every unplanned hour.
Plan
Before the line runs
  • Which equipment is critical to uptime?
  • Cost per hour down, all six layers counted
  • MTBF and MTTR target per machine
  • PM schedule defined with cycle frequency
  • Spare parts stocked to MTTR target
Do
On the floor, every shift
  • PMs executed on schedule — not skipped
  • Stop codes logged at every unplanned stop
  • Failure mode fix followed, not invented
  • Maintenance response time tracked
  • Spares checked and restocked after use
Check
Track drift from plan
  • Actual uptime vs planned — daily
  • MTTR per machine vs target
  • MTBF trending up or down?
  • Full downtime cost tallied per event
Without structured Check: stop logs pulled manually (2 hrs), cost calculated in a spreadsheet (3 hrs), report built for Monday meeting (2 hrs). Line bled Thursday. Decision made Monday. That labor is a cost. The delay is a cost.
Act
Close the loop
  • MTTR exceeded? Root cause and fix the process
  • MTBF dropping? Shorten PM cycle on that machine
  • Spare ran out? Adjust stocking level
  • PM was skipped? Own the cost that came from it
  • Cycle resets with updated maintenance plan
Most plants Plan PMs and skip them when production is busy. Do is inconsistent. Check is a Friday report. Act is a conversation that happens too late. Fourem's four studios run this cycle in one place. Stop codes log in Do. Check is real-time, not a spreadsheet. Act becomes the next shift's updated Plan.
Operations Room
Three lines. Same gap. Different reasons.
Constant Small Stops
Tractor Transmission Assembly Line
Without plan$344K/year
With plan$64K/year
Annual savings$280K+
Read what happened
Heavy Machinery · Long MTTR
Industrial Band Saw Operation
Without plan$387K/year
With plan$43K/year
Annual savings$344K+
Read what happened
Hardware · Software · Network
Consumables Pick/Pack/Ship
Without plan$258K/year
With plan$38K/year
Annual savings$220K+
Read what happened
Cost of Labor — Playbook 03
Cost of Labor
Playbook · Cost Cut #3 of 5
Planned Labor Cost / Unit
$18.50
Built into your product cost at launch
Actual Labor Cost / Unit
$27.80
What you're actually spending per unit
$9.30 over plan on every unit. On 1,000 units/day that's $9,300 a day in labor your margin wasn't built to carry. Most of it isn't overtime. It's idle time, wrong skills at wrong stations, and a line so unbalanced that some workers sprint while others wait.
Where the $9.30 goes — per unit
Idle labor at downstream stations $3.20 · Bottleneck overtime $2.40 · Wrong skill on wrong station $1.60 · Rework from pace pressure $1.10 · Supervisor time managing imbalance $1.00
Total overage / unit $9.30 — hiding inside your labor report as "headcount variance"
Problem
What each role is being asked — and what they actually know
If it was planned upfront
VP / Operations
What is our labor cost per unit vs plan?
$18.50 planned. We know immediately if actual drifts and which stations drove it.
Where is overtime running and why?
Station 4 is our bottleneck — takt time is 68 seconds, cycle time is 84. We're rebalancing this week.
Production Manager
Is the line balanced to takt?
Yes. Each station is within 10% of takt. Bottlenecks are identified and owned.
Do we have the right skills on the right stations today?
Skills matrix is current. Station 6 needs two Level 3 operators — both are assigned.
Supervisor
Which stations are running behind takt right now?
Station 4. I moved one worker from Station 7 to support. Output is recovering.
Who's idle and who's overloaded?
Stations 5, 6, 7 are waiting on Station 4. I know exactly where to flex.
What's actually happening
VP / Operations
What is labor cost per unit vs plan?
We track total headcount cost. Per-unit labor isn't calculated until month-end.
Where is overtime running and why?
Station 4 keeps running long. We're not sure if it's skill, pace, or the process itself.
Production Manager
Is the line balanced to takt?
We set it up at launch. Haven't done a balance study since. Not sure where it stands.
Do we have the right skills on the right stations?
We assign whoever is available. Skill gaps show up as quality problems later.
Supervisor
Which stations are running behind takt?
I can see it on the floor but I can't show it to anyone. Nothing is tracked.
Who's idle and who's overloaded?
Some workers are clearly waiting. I move people around by feel. No data to back it up.
What it costs to run labor at plan
Labor is your highest controllable cost. It's also the most misread — because idle time and line imbalance don't show up as "waste" in any standard report. They hide inside headcount. This cycle makes them visible and keeps them managed.
Plan
Before the shift starts
  • Line balance study — cycle time vs takt at every station
  • Bottleneck identified and owned before production starts
  • Skills matrix current — right skill level per station
  • Headcount per station defined, not just total headcount
  • Overtime budget set with trigger conditions
Do
On the floor, every shift
  • Assign workers per balance plan — not by feel
  • Track pace to takt at each station in real time
  • Flex workers to bottleneck stations before overtime triggers
  • Log every unplanned skill substitution
  • Overtime approved against plan — not verbal OK
Check
Track drift from plan
  • Labor cost per unit — daily, not monthly
  • Which stations exceeded takt and by how much?
  • Idle time per station — is anyone waiting for upstream?
  • Overtime by station vs plan — where did it spike?
Without structured Check: payroll pulls headcount data (2 hrs), production pulls output data (2 hrs), someone ties them together in a spreadsheet (3 hrs). By the time labor cost per unit is calculated, you've already run the next week the same way.
Act
Close the loop
  • Rebalance stations when takt drift is confirmed
  • Cross-train workers for bottleneck stations
  • Update skills matrix when gaps surface
  • Adjust headcount plan when volume changes
  • Cycle resets with updated balance and assignments
Line balance studies happen at launch. Most are never updated. Takt changes when volume changes. Skills change when workers turn over. The line that was balanced 18 months ago is not the line running today. Fourem tracks pace to takt at every station, flags idle time and bottlenecks in real time, and surfaces labor cost per unit before the shift ends — not after the month closes.
Operations Room
Three lines. Same labor overage. Different reasons.
Intricate Assembly · 22 Stations
Ergonomic Task Chair
Assembly
Without plan$31.40/unit
With plan$19.20/unit
Annual savings (100K units)$1.22M
Read what happened
High Skill · Tight Tolerance
Engine Casting
Finishing Line
Without plan$148/unit
With plan$96/unit
Annual savings (18K units)$936K
Read what happened
Highly Sensitive Process
96-Gallon Storage
Container Line
Without plan$8.60/unit
With plan$4.90/unit
Annual savings (200K units)$740K
Read what happened
Cost of Inventory — Playbook 04
Cost of Inventory
Playbook · Cost Cut #4 of 5
Planned Days on Hand
30
Days of stock to cover production without overstocking
Actual Days on Hand
58
What's sitting in your warehouse right now
28 extra days of inventory on hand. On $2M in raw material value, that's $155K in cash parked in your warehouse earning nothing — while the line still stops because the 3 parts you actually need aren't there.
What inventory cost actually includes — per year
Cash carrying cost $155K · Storage & handling $48K · Obsolescence write-off $62K · Line stops from wrong-part shortage $84K · Expedite freight $37K · Search & handling labor $29K
Total annual inventory cost $415K — mostly invisible. None of it shows up on the shop floor report.
Problem
What each role is being asked — and what they actually know
If it was planned upfront
VP / Operations
What is our inventory value vs plan right now?
$2M on hand. 30 days of coverage. Carrying cost is $155K/year — budgeted.
Are we at risk of a line stop from shortage?
Three parts below reorder point — purchase orders already placed, arriving Thursday.
Production Manager
Do we have all parts to run today's schedule?
Yes. Kit check confirmed before shift start. All 32 parts available for today's run.
Which parts are we most likely to run short on?
Parts 7, 14, and 22 — long lead time, high consumption. Min stock levels are set.
Supervisor / Warehouse Lead
Where is every part and how much do we have?
Bin locations are mapped. Quantities confirmed at shift start. Discrepancies flagged immediately.
When do I reorder and how much?
Reorder trigger is defined per part. Quantity calculated by consumption rate and lead time.
What's actually happening
VP / Operations
What is our inventory value vs plan?
We have $2M on hand but don't track carrying cost separately. It's in overhead.
Are we at risk of a line stop?
Don't know until the line stops. Then someone makes calls to expedite.
Production Manager
Do we have all parts for today's schedule?
Usually find out mid-shift when something runs out. No pre-check process.
Which parts are shortage-prone?
The same ones keep stopping us. But we reorder reactively, not by a plan.
Supervisor / Warehouse Lead
Where is every part and how much do we have?
Generally know where things are. Counts are off sometimes. Found out when something's missing.
When should I reorder?
When someone tells me we're running out. Or when the line stops and everyone is asking.
What it costs to hold the right inventory
The goal isn't less inventory. It's the right inventory — right part, right quantity, right location, right time. Every item below is real work with a real price. Business either runs this cycle or keeps paying to hold parts it doesn't need while stopping for parts it does.
Plan
Before the line runs
  • Min/max stock level defined per part
  • Reorder point set by lead time + consumption rate
  • Long lead time parts identified and buffered
  • Kit completeness check before production starts
  • Carrying cost budgeted — not hidden in overhead
Do
In the warehouse, every shift
  • Bin counts confirmed at shift start
  • Kits pulled and verified before assembly begins
  • Reorder triggered at defined point — not when line stops
  • Every receipt and issue logged at time of transaction
  • Discrepancies flagged same shift, not next week
Check
Track drift from plan
  • Days on hand vs plan — weekly, per part
  • Which parts are below reorder point right now?
  • Obsolescence risk — slow-moving parts by age
  • Expedite cost this month vs plan
Without structured Check: warehouse walks the shelves (2 hrs), someone cross-references the system (3 hrs), shortage list built for Monday's meeting (1 hr). Line stopped Friday. Expedite ordered Saturday. Premium freight paid Sunday. Nobody's counting that cost.
Act
Close the loop
  • Shortage? Adjust reorder point and buffer level
  • Overstock? Reduce order quantity or pause reorder
  • Obsolete parts? Write off and remove from plan
  • New part added to BOM? Update plan before launch
  • Cycle resets with current consumption and lead time data
Most businesses know their total inventory value. Almost none know their carrying cost, their shortage-prone parts by lead time, or their obsolescence exposure until it hits the P&L. Fourem tracks inventory consumption against plan in real time, triggers reorder at the right point, and surfaces shortage risk before the line stops — not after it does.
Operations Room
Three operations. Same inventory gap. Different consequences.
32-Piece BOM · Parts Shortage
EV Harness
Assembly
Without plan$312K/year
With plan$44K/year
Annual savings$268K
Read what happened
Multiple Sub-Cells · Long Lead Time
Modular ADU
Assembly
Without plan$528K/year
With plan$96K/year
Annual savings$432K
Read what happened
172-Piece Kit · Sub-Assemblies
Mechanics
Toolset
Without plan$194K/year
With plan$31K/year
Annual savings$163K
Read what happened
Cost of Compliance & Safety — Playbook 05
Cost of Compliance & Safety
Playbook · Cost Cut #5 of 5
Planned Compliance Cost / Year
$86K
Training, PPE, audits, inspections — budgeted and managed
Actual Compliance Cost / Year
$340K
What it costs when compliance is reactive, not planned
$254K over plan. Most of it was never budgeted because it was never expected. One incident, one citation, one failed audit — and the cost structure changes permanently. Insurance goes up. Regulatory scrutiny increases. The line that ran normally last quarter is now under a corrective action plan.
What compliance failure actually costs — beyond the fine
Regulatory fines & citations $48K · Worker injury cost $76K · Insurance premium increase $38K · Production shutdown & remediation $64K · Retraining & corrective action $28K · Legal & management overhead $86K
Total incident cost $340K — from one event. The fine was the smallest part.
Problem
What each role is being asked — and what they actually know
If it was planned upfront
VP / Operations
Are we audit-ready right now?
Yes. Last inspection was 6 weeks ago. All corrective actions closed. Next scheduled in 8 weeks.
What's our recordable incident rate vs plan?
0.8 TRIR. Plan was 1.0. We're ahead — because near-misses are logged and acted on.
Production Manager
Are all workers current on required training?
Tracked by role. Three workers due for refresher next week — already scheduled.
What's the compliance status on every process today?
Daily checklist confirmed at shift start. Any gap flagged before production runs.
Supervisor
When something looks unsafe, what do you do?
Log it as a near-miss. It gets reviewed in 24 hours. I know it won't get buried.
Are all PPE and safety controls in place right now?
Shift start check confirms it. If anything's missing, the line doesn't start.
What's actually happening
VP / Operations
Are we audit-ready right now?
Probably. We haven't had an inspection in a while. Not sure when the last one was.
What's our recordable incident rate?
We track recordables. Near-misses aren't consistently logged so we don't know the trend.
Production Manager
Are all workers current on required training?
HR tracks this somewhere. I find out when someone flags it during an audit.
What's compliance status today?
We assume it's fine unless something comes up. No pre-shift compliance check.
Supervisor
When something looks unsafe, what do you do?
Tell the manager. Or fix it myself. Logging it feels like paperwork that goes nowhere.
Are all safety controls in place right now?
Generally yes. But we don't check systematically before every shift starts.
What it costs to stay compliant and keep workers safe
Compliance cost is the most deceptive cost on this list. When the cycle runs correctly, it's nearly invisible — training logs, shift checks, near-miss reports. When it breaks, one incident rewrites your insurance, your regulatory standing, and in the worst cases, someone doesn't go home. This cycle keeps it from breaking.
Plan
Before the shift starts
  • Compliance requirements mapped per process and role
  • Training schedule current — expiry dates tracked by person
  • PPE requirements defined per station and task
  • Inspection and audit calendar set for the year
  • Corrective action process defined before any incident
Do
On the floor, every shift
  • Pre-shift safety check — controls confirmed before start
  • PPE verified per station before workers begin
  • Every near-miss logged — not just recordables
  • Hazardous process steps followed in documented sequence
  • Training records updated at point of completion
Check
Track drift from plan
  • Near-miss frequency — trending up or down?
  • Training currency — who is overdue right now?
  • Open corrective actions by age and owner
  • Audit findings vs closed — what's still open?
Without structured Check: compliance status lives in three spreadsheets and an HR system nobody shares. Audit prep takes two days of scrambling. Near-misses sit in a notebook. The first signal of a real problem is an OSHA inspector at the door or a worker in the hospital.
Act
Close the loop
  • Near-miss reviewed within 24 hours — root cause logged
  • Corrective action assigned, tracked to closure
  • Training gap found? Schedule filled before next shift
  • Audit finding closed with evidence — not just a note
  • Cycle resets with updated compliance baseline
Most plants track recordable incidents. Almost none track near-misses, training expiry before it lapses, or audit findings to verified closure. Fourem logs near-misses at the floor, tracks training currency by role in real time, and closes corrective actions with evidence — so the next audit is a confirmation, not a scramble.
Operations Room
Three operations. One compliance gap. Very different consequences.
OSHA PSM · EPA · GHS/SDS
Chemical Drum
Filling & Blending
Without plan$618K incident
With plan$74K/year
One incident vs running clean$544K difference
Read what happened
FDA FSMA · HACCP · Allergen Control
Food-Grade
Packaging Line
Without plan$1.2M recall
With plan$92K/year
One recall vs running clean$1.1M difference
Read what happened
NFPA 70E · UL · Lockout/Tagout
Commercial Electrical
Switchgear Assembly
Without plan$880K incident
With plan$68K/year
One arc flash vs running clean$812K difference
Read what happened
One line. One day.
Let's go.
Contact Sales
Joe's Log
Fourem · MOM
Joe's Log
A real shift.
A real floor.

Imagine walking in already knowing.

Nothing to chase. Nothing to guess. Nothing waiting to surprise you at 10am.

This is what that feels like.

— THE LOG —
This is the part most floors never see.
10:36
MRO
LIT-Day
RAD
FBU
QMS
LIVE
Lithia III LOG 283
11/19/2025 · Day
Planned by Pravin Kapse · Accepted by Victor Chung
Target: 1,410 ea · 89.3% efficiency
Suggestion
60 Anode form
Aaron Weir · SBX1 · Cost, Quality
14 min
›
Safety
70 Cap forming
PPE Audit · Victor Chung · Complete
22 min
›
Breakdown
40 Console Draw | pre-formed
RES-622 · Deformed · MTTR 42 min
42 min
∨
Validation
70 Cap forming | utilization
VAL-52 · Method M-7714 · Pass
48 min
›
Training
30 Pellet Cast
Loisa Chaff · TRA-098 · In progress
67 min
›
NO MEETING CALLED
Breakdown
40 Console Draw | pre-formed
RES-622 · Deformed · MTTR 42 min · MTBF 12,960 min
42 min
∨
ID: RES-622 · Victor Chung · 1:33 PM
Console pre-formed — Deformed on entry
MTTR
42 min
MTBF
12,960 min
Units Lost
294
Responded by Victor Chung · 1:33 PM
Time to Respond
2 min
Triaged by Victor Chung · 1:35 PM
"Deformed on entry. Guide worn. Flagged for PM after restore."
Restored by Mario Hamilton · 3:52 PM
Time to Restore
137 min
Trial
24 pcs
"Ran 24 — wanted certainty. Feed guide wear flagged for next PM."
Confirmed by Mario Hamilton · 3:52 PM
Event Details
Units Lost
294
Respond
2 min
MTTR
42 min
MTBF
12,960 min
Quality
10 Cathod Blend | KOH concentration
QA-114 · Potassium Hydroxide out of spec · 28.4% vs 30% target · Lek Amin
54 min
›
People
90 Print & Pack | Kat
RES-389 · Sick · MTTR 53 min · Ruby Grande responded
53 min
›
Breakdown
50 Seal Pellet | stamping
RES-438 · Lost clamping · MTTR 66 min · MTBF 18,720 min
66 min
›
Training
12 Blend Drying
TRA-125 · Joey Deluca · Method Rev 3 · Ruby Grande
139 min
∨
Event ID: TRA-125 · Ruby Grande · 10:45 AM
Workstation
12 Blend Drying
Trainee
Joey Deluca
Method
Rev 3
1
I do it
Ruby Grande · 10:45 AM
"Showing Joey the blend cycle. Pre-heat 3 min before feed — don't skip."
2
We do it
Ruby Grande · 11:33 AM
"Joey hit spec first try. Pacing good. Watching the dwell time."
3
You do it
Ruby Grande · 1:04 PM
"Running independently. Speed right. No hesitation. Looks qualified."
✓
Confirmed Qualified · Ruby Grande · 1:05 PM
"Joey qualified on WS 12. Added to certified list. Available next shift."
Event time
139 min
Units Lost
0
Shift
Day
Breakdown
40 Console Draw | precut steel
RES-396 · Rust on plates · MTTR 97 min · MTBF 25,920 min
97 min
›
Quality
Incoming | Graphite powder
QA-089 · Purity 96.1% vs 99% spec · Lot GR-2241 held · Pravin Kapse
37 min
›
PM · Method
10 Cathod_Blend
Gemba Walk · Self · 8 hrs · 3-week schedule
480 min
›
Suggestion
40 Console Draw
Mario Hamilton · SBX3 · Safety, Delivery
31 min
›
Milk Run
Milk Run #2
Ruby Grande · 5 Kanbans · 327 min total
327 min
∨
50 Seal Pellet | hot melt
Open
Pick
Drop
Hold
60 Anode form | Potassium hydroxide
Open
Pick
Drop
Hold
70 Cap forming | preformed cap
Open
Pick
Drop
Hold
100 Palletizing | Shrink wrap
Open
Pick
Drop
Hold
100 Palletizing | Pallet
Open
Pick
Drop
Hold
Milk Run Summary
5
Kanbans
327 min
Total
65 min
Mean
1
On Hold
0 min
Hold Loss
Breakdown
60 Anode form | Potassium feed
RES-512 · Flow restricted · MTTR 87 min · MTBF 6,480 min
87 min
›
PM · Machine
50 Seal Pellet | stamping tooling
Expert · 45 min · MTBF 9,720 min · 9-day schedule
45 min
›
Safety
20 Cathod Mix
Chemical handling audit · Lek Amin · Complete
25 min
›
PM · Quality
Incoming | Barium Sulphate
QA-Audit · Batch BSO-4419 · Particle size D50, moisture, purity · Lek Amin
28 min
›

This is what all of that adds up to.

Outcome
Project Volume620,000 ea
Planned Bottleneck20 Cathod Mix
Planned Efficiency89.3%
Planned Capacity1,410 ea
Actual Bottleneck13 Decaking
Actual Efficiency91.4% +2.1%
Actual Capacity1,410 ea
Output to Date155,850 ea
Log DateNov 19, 2025 · Day
Close Log
WIP Summary
10 Cathod_Blend
12 Blend Drying
13 Decaking
Actual WIP · Standard WIP: 25
25
Report
100%
Availability
100%
Quality
91.4%
Performance
91.4%
OEE
100%
Stations
WS 13
Bottleneck
95%
Kanban Ret.
1
On Hold
FrontlineEvery breakdown. Back up faster than last time.
SupervisorEvery shift. Ships more efficiently than last.
Plant ManagerPeople and system. Smoothly delivering targets.

Fourem is MOM. Right people set up the shift. Right people run it. When something breaks — anyone can step in.

$22.95
per shift · per line · unlimited users
The 40 people who never set foot on the floor but made it ready — they are all in this log.

That part is priceless.
When you have Fourem,
you only have Fourem.
Fourem

We'll send you a clean link to this log.
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Fourem · ROI
From paper cups to drive units — Scaling manufacturing has one strategy.
“Hiring Plan”
RIGHTpeople to keep everyone above on track
RIGHTpeople to close the right gaps
RIGHTpeople to figure out the right gaps
RIGHTpeople to connect the right tools
RIGHTpeople to buy the right tools
Maybe the next hire breaks the code.
Or: one framework, a lean team, half the time.
With Fourem
This is Manufacturing Operations Management.
01
The tool
02
Right responsibilities
03
Right targets
04
Right gaps
Dozens of production lines. In your pocket.
See how