Operations
8 min
The hidden factory: the work your operating model doesn’t show
In most businesses, a fifth of all effort goes into rework, chasing and checking that no process map shows.
Theo Marchetti
Senior Partner
Every organisation has a second factory running inside the first one: the rework, the chasing, the spreadsheets that fix what the system gets wrong.
How to find it
Follow one order, one claim or one invoice from start to finish and count every touch. The gap between the process map and reality is the hidden factory.
What to do about it
Fix the first error, not the tenth check. Most rework starts with one missing field at the start of a process.
