Manufacturing Challenges ShadowOps Solves

Four common scenarios. Four ways ShadowOps gives you visibility and control before it's too late.

Challenge 1: Late Jobs

The Signal

Job SKU-4521 (customer order, due Friday) is at 78% risk of missing its date.

ShadowOps flags this on Tuesday morning—three days before the customer even calls asking "where's my order?"

Why It's Happening

  • Work Center 3 (bottleneck for finishing) is overbooked
  • Three jobs ahead of SKU-4521 scheduled back-to-back
  • No buffer between operations
  • Estimated completion: Monday (1 day late)

Recommended Actions

  • Move Job 4518 (lower priority) to Work Center 4 (longer lead time, but clears capacity)
  • Run overtime on Work Center 3 Wednesday & Thursday (+4 hours = catch up)
  • Contact customer: "On track for Friday, but tight. Expedite possible for +$500."

Who Gets Notified

  • ✓
    Production Manager
    Action needed now
  • ✓
    Scheduling
    Reschedule Job 4518
  • ✓
    Customer Service
    Have customer conversation ready
  • ✓
    Finance
    Potential overtime cost

Challenge 2: Material Shortages

The Signal

Material MT-847 (steel subassembly) will be short by 12 units in 8 days.

ShadowOps detects this now. Supplier lead time is 14 days. You can still expedite.

Why It's Happening

  • Safety stock for MT-847 is only 20 units
  • Three new jobs entered this week, all using MT-847
  • Current inventory: 32 units
  • Forecasted demand (next 10 days): 44 units
  • Shortage: 12 units by Day 9

Recommended Actions

  • Expedite PO-5643 (24 units MT-847) from normal lead (14 days) to expedite (7 days). Cost: +$300.
  • Delay Job 4622 (lower priority) by 3 days to reduce demand pressure
  • Consider alternative material (MT-846, slight upcharge) for Job 4525 to split usage

Who Gets Notified

  • ✓
    Procurement
    Place expedite order now
  • ✓
    Production Manager
    Plan alternative or delayed job
  • ✓
    Finance
    Expedite cost approval
  • ✓
    Customer Service
    If shortage affects deliveries

Challenge 3: Machine Downtime

The Signal

Lathe 7 scheduled for maintenance Friday, 8 AM–1 PM (5 hours). This cascades.

ShadowOps models the ripple effect immediately and flags at-risk jobs and work centers.

Ripple Effects

  • 5 jobs queued for Lathe 7 on Friday
  • Downtime pushes 3 jobs to Monday
  • Monday now overbooked by 6 hours
  • Milling (downstream) loses input, sits idle Tuesday morning
  • 2 customer orders at risk

Recommended Actions

  • Run Lathe 7 Thursday evening to build buffer (3 extra hours)
  • Move lowest-priority job (4518) to Lathe 6 Friday if capacity exists
  • Notify Milling team: delayed feed on Friday, plan alternative work Monday AM
  • Brief customer: "On track, but tight timeline Tuesday. Can expedite +$800 if needed."

Who Gets Notified

  • ✓
    Production Manager
    Rework schedule
  • ✓
    Maintenance
    Confirm downtime, offer alternative timing
  • ✓
    Milling Supervisor
    Prep for idle time, plan contingency
  • ✓
    Customer Service
    Customer notification if needed

Challenge 4: Labor & Skill Constraints

The Signal

Next week: 3 jobs need certified welders. You have 2 certified staff. One is on vacation Wednesday–Friday.

ShadowOps identifies the bottleneck and suggests mitigation 10 days out.

The Constraint

  • Job 4501 (welding, 8 hours) needs certified welder, Mon–Tue
  • Job 4523 (welding, 6 hours) needs certified welder, Wed–Thu
  • Job 4598 (welding, 4 hours) needs certified welder, Thu–Fri
  • Certified staff: 2 FTE, 1 on vacation Wed–Fri
  • Shortage: 6 hours (1 full day)

Recommended Actions

  • Delay Job 4598 by 1 week (less critical customer date)
  • Pull forward Job 4501 to start Monday morning (use both welders Mon–Tue)
  • Hire temp certified welder for Wed–Fri (lead time: 3 days, cost: +$2,100)
  • Schedule cross-training for new staff (start 2 weeks)

Who Gets Notified

  • ✓
    Production Manager
    Staffing adjustment
  • ✓
    HR
    Temp hire request, lead time planning
  • ✓
    Scheduling
    Job reschedule
  • ✓
    Finance
    Temp labor cost approval
  • ✓
    Customer Service
    Job 4598 delay notification

The Pattern

In each case, ShadowOps gives you early visibility, explains the root cause, and surfaces options—so you can act before your customer is affected.

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