Operational Diagnosis
We analyse your operation to identify inefficiencies, visibility gaps and improvement opportunities. Field work on the shop floor, evidence-based analysis and actionable deliverables: an operational assessment, a systems map and prioritised quick wins.
Operational diagnosis: overview
An operational diagnosis is a structured analysis of how a plant actually runs, rather than how its procedures say it runs. We analyse your operation to surface inefficiencies, visibility gaps and improvement opportunities before any technology is on the table. The work covers four intersecting angles: material and work flows, data and records, the existing system landscape, and losses (downtime, scrap, defects, reduced speed) measured against theoretical capacity.
The method runs in four phases: scoping, field work on the shop floor, evidence-based analysis, and prioritised conclusions. You receive three deliverables: an operational assessment with a maturity rating, a systems map showing how information really moves between ERP, SCADA, spreadsheets and manual records, and a short list of quick wins you can act on straight away at low cost.
The diagnosis is the entry point to the Captia consulting method: its findings feed the transformation roadmap and the systems map becomes the basis for architecture design, so later projects start from verified facts rather than assumptions. If your plant is in the province of València, our page on Industry 4.0 consulting in Valencia explains how we chain these phases on the ground.
How it connects to the system
This solution fits the Captia architecture: it defines the diagnosis and prioritisation frame that activates Connect, AI, Energy and Service.
Key concepts
Other solutions
- Architecture Design
We design the technical and functional architecture of the solution adapted to your current infrastructure: which systems integrate, how data flows between plant and management and which pieces are needed before investing in new technology.
- Transformation Roadmap
We define a prioritised, actionable Industry 4.0 transformation plan aligned with your execution capacity. We start from the diagnosis findings and order initiatives by impact, effort and technical dependencies, in a clear sequence of phases.
- Industrial Automation
We identify and design the industrial processes that can be automated to gain efficiency. We assess each case on operational criteria, with no product catalogue conditioning the recommendation, and document the basis for the decision.
Frequently asked questions
- How long does an operational diagnosis take?
- It depends on the size of the plant, the number of lines and how many systems need reviewing. A diagnosis scoped to one area usually takes a few weeks; assessing the full operation needs more time in the field and in analysis. We agree the scope up front and give you a realistic estimate before work starts.
- Do I need sensors or digital systems in place?
- No. The diagnosis starts from whatever exists, even if records are spreadsheets or paper forms. One of its purposes is precisely to determine which data is missing and what would be needed to capture it. If you already run MES, SCADA or an ERP, we include them in the analysis.
- How does the diagnosis differ from the transformation roadmap?
- The diagnosis answers "where are we and why": it identifies inefficiencies, visibility gaps and opportunities. The roadmap answers "what do we do and in what order": it turns those findings into a prioritised plan aligned with your execution capacity. They are consecutive phases.
- Does the diagnosis commit me to further projects?
- No. The deliverables are yours and are written so that any team, internal or external, can act on them. Many plants tackle the quick wins with their own resources. If you later want to continue with architecture design or implementation, we build on the work already done.