maji Tools
Tools that solve common problems we see in most factories
Starting with labour control: visibility of labour spend against standard, broken out into plan attainment, flatness, overtime, crewing and control.
maji by majaco
We leave the tools that help you keep improving.
We sell an outcome: an improvement in your capacity, labour, yield or giveaway. maji is how we make that improvement stick. Instead of spreadsheets that break and fall over, you get robust, bespoke tools and reporting. They are designed around your biggest problem, then built and maintained by the team that found it.
What maji is
Bespoke tools built to solve your biggest problems, permanently
maji Build
One-off solutions built for your specific operation
We don’t push you towards a product that doesn’t quite fit. We build the thing that gets to the heart of what you need, and we maintain it for you on an ongoing basis.
maji Works
Speeding up our delivery on site
maji lets us build faster, so you see your performance clearly in weeks, not months. Then it changes how your site runs: the numbers you report and how you report them. The old spreadsheets are retired, not left running alongside.
In practice
Built during the project, supported with an ongoing subscription
The dashboards and tools we build during a project stay with you afterwards. A subscription covers keeping them running and developing them as your business changes.
Why it matters
Most factories have hidden capacity potential
Understanding why this can happen is the first step.
The problem
A soft standard hides the real potential
Most lines are measured against what they usually achieve, not what they could achieve. Hit that number and the line looks efficient, even when it runs well below what the equipment can do.
Why it persists
Knowing the method isn’t enough
Consultancy often leaves frameworks and presentations rather than day-to-day capability. Knowledge sits with a few people and in scattered spreadsheets. Once support ends, improvement stalls and the soft standard creeps back.
What changes it
Measure the real gap, and keep measuring it
We measure every line against its bottleneck speed, the fastest rate it can sustain. maji keeps the gap visible in hours and pounds, so teams can prioritise, build lasting skills and keep improving.
maji tools library
Free tools from the majaco method
Each tool encodes part of how we work, so your team can use it on its own lines.
Calculator
Speed-Downtime Calculator
Find the optimal line speed where PPLH peaks, accounting for speed-induced reliability and quality degradation. Built for sales-constrained environments.
Open toolProblem solving
Split Solve
Systematic problem solving using MECE splits to identify root causes: define, split, understand. Export findings as PDF.
Open toolGuide
Manufacturing Psychology
Seven cognitive and organisational barriers that systematically prevent manufacturers from capturing 30 to 60% available capacity improvements.
Read guideGuide
Process Control Methodology
Strategic buffer placement, mathematical sizing and constraint protection in multi-stage production systems. Expected: 20 to 40% throughput improvement.
Read guideCalculator
Batch vs Flow
One-piece flow sounds great in theory, but the maths of coupled systems tells a different story. An interactive calculator showing why context matters.
Open toolFramework
Time Hierarchy Framework
A methodology for measuring manufacturing performance through time-based decomposition and constraint-state-dependent financial valuation.
Explore frameworkReference
Efficiency Formulas
Quick reference for core majaco methodologies: OEE, PPLH, TEEP, labour efficiency and time-based Lost Time analysis.
View formulasGuide
TOC Subordination
Why the hardest part of Theory of Constraints isn’t finding the bottleneck: it’s getting everything else to serve it. Drum-Buffer-Rope explained.
Read guideField tool
RAG Study Tool
Red Amber Green production line study with live uptime tracking. Capture and categorise downtime events in real time during line observations.
Open toolSecure sites
Go to your majaco site
Every client, and every majaco team tool, has its own secure site at name.majiai.co. Choose a team site or type your company's name, then sign in with your work email.
Talk to majaco
Start with a conversation.
Tell us about the line, the shift or the number that is bothering you. We will come back within one working day.