You can put a credible number on manual work in one week, without disrupting operations.
Follow One Unit Through the Process
Pick one depot, one plant, one team. Map the workflow as it actually runs, not as the SOP says it runs. Two working sessions with the people who do the work, plus a look at the real data, is usually enough.
Cost It as It Runs Today
Time per item, times volume, times loaded cost. That is the baseline. Use ranges where the data is thin and say so. A hedged number with named assumptions is worth more than a precise number nobody believes.
Size What Could Clear Itself
Ask one question of the data: what share of items matches its reference exactly? That share, priced against the baseline, is the opportunity. The rest is exceptions, and exceptions keep a person.
- Use the client’s own data, never industry benchmarks alone.
- State every assumption in writing.
- Give a range, not a point estimate.
- End with a go or no-go recommendation, including when the answer is no.
A week is enough to decide whether the build deserves money. Spend the week before you spend the year.