The fix only one person knows

This is the planned outline of the flagship report. The report itself is a placeholder; the chapters listed on this page describe the questions it will answer, not findings.

On many sites, a few technicians fix the faults that stop a line

On many sites, the faults that stop a line are resolved by a few senior technicians whose method lives in their hands and their ears, not in the SOP. The report will test how widely that holds, and look at how operations leaders turn that know-how into something the next shift can use, starting with the tasks that would hurt most to lose.

Exhibit 1

Illustrative data

In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service

Skilled maintenance headcount by years of service, illustrative bottling plant

14

9

6

7

10

17

21

16

0–23–56–1011–1516–2021–2526–3030+

View the data

In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service (Skilled maintenance headcount by years of service, illustrative bottling plant)

Category	Value
0–2	14
3–5	9
6–10	6
11–15	7
16–20	10
21–25	17
26–30	21
30+	16

Link to this exhibit: In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service

Each chapter names the task, the machine and the role

It sets out the capture methods plants use, what each one keeps and what it loses, and the evidence behind every claim. Every chapter ends with something a plant team can try next week.

Chapter openers

What the expert listens for, drawn onto the machine

Each chapter opens on the equipment it is about, with the know-how attached as callouts.