PROGRAM EXECUTION DIAGNOSTIC

Execution Reality Reconstruction — Manufacturing & Production
Operational Execution Architecture Service — Non-Licensed (Not Engineering / Not EPC / Not Project Management)

What Is a Program Execution Diagnostic?

A Program Execution Diagnostic is a structured reconstruction of how manufacturing execution actually behaves under load—line by line, shift by shift, constraint by constraint.

It does not analyze what production is intended to do.
It analyzes what production actually does—handoff by handoff, decision by decision, defect by defect.

Most organizations operate on an assumed production model derived from routings, ERP logic, work instructions, dashboards, and “capacity plans.” In reality, execution behaves differently:

Constraints shift and hide behind expediting
WIP accumulates in non-obvious queues
Engineering change activity destabilizes flow
Quality escapes recur through propagation pathways
Decision latency stalls throughput at escalation choke points
Supplier variability amplifies instability inside the line

The Program Execution Diagnostic exposes the gap between the planned production model and execution reality.

Its purpose is to make manufacturing execution physics visible so leadership can govern reality instead of debating symptoms.

Why This Is Needed

Manufacturing failure after technical validation is rarely caused by one defect or one person.
It is caused by execution architecture mismatch.

Common conditions include:

• Production targets missed despite headcount and capital increases

• Overtime rising while output remains unstable

• Bottlenecks moving weekly

• Metrics improving while delivery credibility worsens

• Corrective actions repeating without eliminating recurrence

• Engineering, quality, and operations disagreeing on root cause

Traditional tools do not reveal this:

• KPIs show outcomes, not mechanisms

• Dashboards hide queues, decision stalls, and propagation

• ERP reflects designed logic, not lived behavior

• Process maps describe how work should flow, not how it does

Without an execution diagnostic, leadership “optimizes” around false assumptions and increases instability.

Why Execution Architecture Matters

Execution architecture determines:

• Whether throughput increases with volume or collapses under load

• Whether quality improves or fails at scale

• Whether decisions land in time to prevent cascading failure

• Whether variability is absorbed or amplified into systemic instability

• Whether partners/customers/DOE programs experience predictable delivery

If execution architecture is wrong:

• Scaling makes output less predictable

• Quality systems degrade under volume

• Pilot-to-production transitions fail

• Schedule credibility collapses and recovery becomes expensive

If execution architecture is corrected:

• Constraints stabilize

• Variance is suppressed before it cascades

• Decisions resolve without throughput loss

• Output becomes predictable before optimization begins

How TJEG Performs the Diagnostic

TJEG performs Program Execution Diagnostics using operational execution architecture methods, not generic “lean assessments.”

1. Execution Reality Reconstruction
   Reconstruction of how production actually runs across:

   • Lines, cells, and shifts

   • Queues, rework loops, and wait states

   • Handoffs between engineering/quality/ops/supply
     Based on direct observation, artifact review, and reality mapping—not workshops.

2. Constraint & Queue Validation
   Identification of:

   • True primary and secondary constraints

   • Hidden queues and WIP instability mechanisms

   • Where capacity claims diverge from usable throughput

3. Decision Physics Mapping
   Identification of:

   • Where escalation stalls throughput

   • Who holds real decision authority versus declared authority

   • Where time-based degradation enters execution

4. Quality Behavior & Propagation Tracing
   Tracing of:

   • Where defects are introduced

   • How rework, escapes, and containment failures propagate

   • Where inspection increases without stability

5. Interface & Accountability Failure Mapping
   Identification of:

   • Cross-functional handoff breakdowns

   • Ownership ambiguity and rework injection points

   • Informal workarounds bypassing formal control

What This Delivers

At completion, leadership receives:

• A validated execution reality map (actual production mechanics)

• A constraint register (primary/secondary constraints + why they behave that way)

• A queue/WIP instability map (where work accumulates and why)

• A decision latency & escalation choke-point map

• A quality propagation map (defects/rework/escapes pathways)

• A prioritized fault-line list suitable for executive action

• A stabilization sequence that defines what must be controlled first

This replaces “debate and expediting” with decision-grade ground truth.

Who This Is For

This service fits organizations including but not limited to:

• Battery manufacturers and BESS fabricators/integrators

• Module, pack, enclosure, and power electronics manufacturers

• Advanced manufacturing startups (pilot → commercial)

• Contract manufacturers under schedule/yield/quality pressure

• DOE-funded or partner-dependent programs with delivery exposure

Engagement Characteristics

• Rapid, production-grounded reconstruction

• Deployable at line, facility, or multi-site level

• Standalone or embedded into broader TJEG engagements

• Operational execution architecture only

• Non-financial, non-legal

Cost & Commercial Structure

Program Execution Diagnostic is a fixed-scope diagnostic engagement.

Typical range: $35,000 – $95,000
Final pricing is determined by facility span, number of lines/shifts, program complexity, and the speed required.

Creditable toward downstream TJEG execution-architecture engagements when initiated within the agreed credit window.
No percentage-based fees. No success fees. No contingent compensation. No equity participation.

Compliance Boundary

TJEG provides operational execution architecture only.

This service does not include:

• Licensed engineering design, stamping, or engineering-of-record services

• EPC, construction management, or contractor-of-record roles

• Project management ownership

• Manufacturing engineering ownership or sign-off authority

• Quality certification, regulated audits, or certification representation

• Legal, financial, accounting, valuation, or investment advisory

• Claims or certifications of regulatory compliance

Work is conducted in accordance with U.S. export control requirements, OFAC regulations, and global anti-corruption frameworks.

Start the Diagnostic

If production performance does not match planning assumptions, this is the correct entry point.

Initiate Program Execution Diagnostic →
(Leads to intake: production environment, scale stage, constraints, quality symptoms, delivery exposure)