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Overtime, Backlogs, Missed Orders. What’s It Really Costing You?

The answer is in the numbers. Companies that measured the cracks stopped the bleeding and uncovered real capacity. The stats below are proof of what’s possible when you act.

$ 0 M
in annualized value recovered across audits
0 %
more throughput unlocked on existing assets
0 %
On-Time-In-Full (OTIF) achieved in under two months
0 %
less time spent rebuilding schedules
Get Your Free Scheduling Audit

Trusted by Industrial Leaders Who Can’t Afford Uncertainty

Logo of Canadian Natural Resources Limited — black and blue yin-yang style droplet with a maple leaf inside.
Logo of Puratos, a global food manufacturing company specializing in bakery, patisserie, and chocolate solutions.
Logo of TAQA, an industrial manufacturing company known for innovation in energy and production efficiency.
Logo of OceanaGold Corporation — black silhouette of a miner’s head with gold
Logo of Aura Minerals — lowercase
Logo of Vale S.A. — stylized green and yellow “V” symbol with
Logo of Sherritt International — bold blue “sherritt” in all lowercase letters.
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You’re Losing More Than You Think

Every planner, manager, and executive knows the schedule breaks. What you don’t know is how much it is really costing. These are the cracks your audit will expose.

Factory supervisor in a hard hat and safety vest reviewing production schedules on a computer screen and clipboard inside a warehouse.

Schedules Collapse by Tuesday

Plans start strong but collapse within days. One machine goes down, a rush job jumps the line, or someone calls in sick — and the whole schedule unravels. Overtime rises, delivery dates slip, and managers spend hours fighting fires.

What this causes
  • ❌ Unplanned overtime and rising payroll
  • ❌ Missed commitments and slipped OTIF targets
  • ❌ Constant rescheduling and lost planner time
  • ❌ Lower morale across teams

Your audit will reveal how often these breakdowns are costing you capacity and cash.

Stressed office worker sitting at a desk with his head in his hand, surrounded by paperwork and files.

Throughput Left Untapped

Most plants believe they are maxed out. In reality, poor sequencing, idle pockets, and long changeovers hide ten to fifteen percent of capacity. That is lost revenue every week. Many leaders approve CapEx they do not need, because the headroom is invisible.

What this causes
  • ❌ Lost revenue from orders you could have delivered
  • ❌ Unnecessary CapEx before existing assets are maximized
  • ❌ Underutilized operators and machines
  • ❌ Bottlenecks that shift and stay hidden

Your audit will surface where capacity is being left on the table in your plant.

Two employees in a warehouse office looking at a computer screen, one speaking urgently on two phones at once.

Planners Say Yes, Floor Teams Say No

Planners commit to orders, floor teams push back on execution, and meetings turn into debates. Without shared truth, every change sparks conflict. Trust erodes, and customers see late deliveries while internal teams blame each other.

What this causes
  • ❌ Slower decisions and constant escalations
  • ❌ Schedule churn and version confusion
  • ❌ Finger pointing when delivery dates slip
  • ❌ Frustration between planners and operators

Your audit will show where misalignment between planning and execution is draining time and trust.

Business professional at a cluttered desk reading documents with a concerned expression.

Payroll Rises Without Better Results

Overtime becomes the default fix. Costs rise by fifty percent above base rates, yet throughput does not improve. Teams are burned out, margins shrink, and the cycle repeats week after week.

What this causes
  • ❌ Persistent cost creep on every busy week
  • ❌ No improvement in schedule attainment
  • ❌ Burnout and turnover on critical lines
  • ❌ Less time for improvement initiatives

Your audit will quantify the real cost of overtime in your operation.

Firefighting

Hidden Capacity

Office vs Floor

Overtime Costs

“The biggest impact so far has been the operational visibility NTWIST provides. Our operators now have a clearer understanding of what better performance actually looks like -  something we didn’t fully have before. This insight is helping set the stage for the next phase of performance improvement.”
— Gordon Art Meyer, Manager Technical Services - Automation, Downstream, Suncor Energy Logistics Corporation

What You Will Get From the Audit

Step 1 → Baseline Snapshot

We capture how your current schedule is really performing against demand and disruptions. This is the hard truth of where time, labor, and output are slipping away.

Step 2 → Bottleneck Detection

We expose the choke points hiding in your process — the idle gaps, the long changeovers, the resource clashes. These are the silent killers of throughput.

Step 3 → Scenario Modeling

We stress test your schedule against the shocks you face every week: a rush order, a sick call, a machine down. You see how fragile the current plan is, and how quickly the cracks spread.

Step 4 → Actionable Report

You walk away with a short, blunt report that quantifies lost capacity, wasted overtime, and the delivery risk you are carrying today. It is a clear roadmap out of firefighting.

The Audit Is Free, Fast, and Actionable

Every week you wait, you are losing capacity, burning payroll on overtime, and risking customer trust. The audit shows you exactly how much. In just a few days, you will receive a blunt, data-backed view of where time, money, and output are slipping away — and what you could recover.

Your audit will include
  • ✔ A reality check on your current schedule and constraints
  • ✔ A quantified view of hidden capacity and wasted effort
  • ✔ Scenarios that prove how disruption derails your plan
  • ✔ A short report that shows the cost of waiting another week
Get Your Free Scheduling Audit

Every Week You Wait, the Costs Climb

Overtime bills pile up. Customers lose trust. Teams keep firefighting instead of improving. The cracks in your schedule will not fix themselves — and every lost week makes recovery harder.

Clock icon with a red upward arrow and dollar sign, symbolizing rising overtime costs.

Rising Overtime, Shrinking Margins

Overtime fills the gaps when schedules fail, but it rarely improves output. Payroll rises by 50% above base rates while margins erode. Each week of delay means more cost with no gain.

Three out of five stars rating with a red thumbs-down symbol, representing customer dissatisfaction and lost trust.

Customers Losing Confidence

Missed commitments ripple through your customer base. A single late order can damage trust that took years to build. The longer the cracks remain hidden, the harder it is to win that trust back.

Person icon with a low battery symbol above the head, representing team stress and burnout.

Teams Burning Out

Planners spend hours reshuffling spreadsheets. Operators lose confidence in the plan. Stress rises, turnover follows, and improvement projects stall. Each week of firefighting drains energy your team could spend moving forward.

It’s Not Just Possible. It’s Proven.

Manufacturers like Puratos uncovered hidden capacity, cut overtime, and stabilized delivery in weeks — not months. The same cracks are in your schedule right now.

Case study document highlighting NTWIST’s results for Puratos, showing 29% throughput lift in food manufacturing with zero infrastructure change.

Puratos Unlocked 29% More Throughput Without Adding Machines

Puratos was struggling with unpredictable schedules, constant rescheduling, and friction between planners and plant managers. Orders slipped, overtime ballooned, and nobody trusted the weekly plan.

By running an audit and deploying NTWIST’s Dynamic Scheduler, they gained a live, adaptable schedule that balanced machines, operators, and changeovers in real time.

Outcomes

  • 📈 29% more throughput on existing assets
  • 📦 On-Time-In-Full (OTIF 95%) achieved in under two months
  • ⏱ 85% less time wasted rebuilding schedules
  • 💰 ROI in just 45 days

Puratos proved what most plants suspect — the hidden capacity is already there. The audit is how you uncover it.

Get Your Free Scheduling Audit

Trusted by Industrial Leaders Who Demand Results

When the stakes are high, leading companies trust NTWIST to turn operational data into measurable outcomes.

By highlighting performance gaps and surfacing new benchmarks, NTWIST is giving our team the clarity needed to move beyond intuition and toward measurable improvement. We're now in a stronger position to define and pursue the next phase of operational excellence.

Gordon Art Meyer

Manager Technical Services | Suncor Energy Logistics Corporation

NTWIST’s AI model increased potential profit in 42% of operating hours and corrected off-target conditions in another 17%. With further refinement, even greater stability and profit gains are expected.

Cory Kasinski

Former Head of Project Evaluations | Sherritt Technologies (via ALTA Conference)

We saw NTWIST’s platform as a strong fit for Clydach because it could improve process consistency without requiring disruptive infrastructure upgrades.

Peter Martin

Technical Manager | Vale Europe Limited

Questions About the Audit?

Is the audit really free?

Yes. There is no cost, no contract, and no disruption to your operations.

How long does it take?

Most audits are completed within a few business days, with a short report delivered to you right after.

Do we need to change our systems or processes?

No. We work with your existing scheduling data — spreadsheets, ERP, MES — whatever you use today.

What will we actually receive?

A concise report that quantifies hidden capacity, wasted overtime, and delivery risk, plus next steps to stabilize your scheduling.

Is our data safe?

Yes. We treat your operational data with enterprise-grade confidentiality and security.

Request Your Free Scheduling Audit

You know the pain of firefighting every week — growing backlogs, missed orders, rising overtime, and stressed teams. These cracks cost more the longer they are ignored.

The audit puts hard numbers on what is slipping away in your plant and shows how much you could recover. It is free, fast, and requires no system changes.

Every week you wait is capacity lost. Start now and see where you stand.