Conceptual connected industrial systems
THE DECISION LIBRARY

One clear question.
A practical decision.

Nine visual tools for CEOs and CPOs. Each uses a hypothetical operating example to connect the action, numbers and next step.

Guru Bandekar
Conceptual Across the enterprise illustration
01 / Across the enterprise / HYPOTHETICAL

Buy now or test first?

A planning system promises lower overtime. The benefit has not been tested.

Run the pilot first
$20kpilot cost
$240ktotal cost over 3 years
$360k claimed benefit
3-year estimate
Pilot before rollout

Unproven benefit → test before committing $240k.

See the working exampleBuy now or test first? — hypothetical exampleFULL COST$240k over 3 years, includingrolloutCLAIMED BENEFIT$360k over 3 years — stillunprovenMISSING PROOFWill planners use it and reduceovertime?BOUNDED TEST$20k pilot; already included inthe $240k

Set the pilot success target. Measure overtime and planner use.

Approve rollout only after a credible test supports the benefit, cost, controls and exit plan.

Owner: Accountable business owner

Conceptual Supply chain illustration
02 / Supply chain / HYPOTHETICAL

When can we supply enough parts?

Start of Day 1: the supplier stops. The factory needs 100 parts every day.

Cover the shortage from Day 15
1,560parts short during recovery
Day 35full daily supply returns
Day 14 · stock ends
Day 18 · qualified
Day 24 · 40/day arrives
Day 35 · 100/day arrives

Days 15–23: 9 × 100 = 900 short. Days 24–34: 11 × 60 = 660 short. Total: 1,560.

See the working exampleWhen can we supply enough parts? — hypothetical exampleDAY 141,400 usable parts run out atthe end of the dayDAY 18Second source passesqualification — no parts hereyetDAY 24 · RAMP-UP STARTSFirst delivery; usable arrivalsstart at 40 parts/dayDAY 35 · FULL VOLUMERamp-up complete: usablearrivals reach 100 parts/day

Find extra supply or agree production/customer changes. Recheck arrivals daily.

Days 15–23: 900 parts short. Days 24–34: 660 short. Total: 1,560. Assumes 100/day demand and no other arrivals.

Owner: Business continuity owner

Conceptual Supply chain illustration
03 / Supply chain / HYPOTHETICAL

Can a second source help in time?

From today, stock lasts six weeks. The replacement supplier is not ready.

Prepare the new supplier; cover the gap
6 weeksuntil stock runs out
Week 12full deliveries, from today
Pass testing · week 8
Full deliveries · week 12
Check arrivals during ramp-up

Stock runs out after week 6; the new supplier reaches full deliveries in week 12.

See the working exampleCan a second source help in time? — hypothetical exampleSTOCK LASTS6 weeks at planned factorydemandQUALIFICATIONNew source needs 8 weeks to passtestingFULL SUPPLYRamp-up + shipping take untilweek 12SEPARATE FAILURE RISKDifferent upstream maker;capacity checked

Confirm testing, ramp-up and deliveries. Agree a separate shortage plan.

It can reduce future dependence, but cannot prevent this shortage alone. Confirm partial-volume arrivals week by week.

Owner: Supply-chain business owner

Conceptual Procurement illustration
04 / Procurement / HYPOTHETICAL

Which offer costs less in use?

Two qualified suppliers quote the same part. We buy 100,000 a year.

Choose B if the cost checks hold
$10.30B: full cost per part
$10k/yearestimated yearly saving
A · $9.50 quoted
B · $10.00 quoted
Compare full cost

100,000 parts × ($10.40 − $10.30) = $10,000/year.

See the working exampleWhich offer costs less in use? — hypothetical exampleSUPPLIER APrice $9.50 + freight $0.30 +quality $0.40 + tooling $0.20 =$10.40/partVSSUPPLIER BPrice $10.00 + freight $0.10 +quality $0.10 + tooling $0.10 =$10.30/partCHECKSame scope and volume; quality,capacity and delivery verified

Verify freight, defect and tooling costs. Award to B if the figures hold.

100,000 × $0.10 = $10,000. Quality costs are estimates; tooling is allocated over the same volume.

Owner: Business sponsor with procurement

Conceptual Procurement illustration
05 / Procurement / HYPOTHETICAL

How much saving actually happened?

The price drops by $0.50 a part. We buy fewer parts than planned.

Report the $30k net cost benefit
$30knet cost benefit this year
$50kplanned saving this year
80,000 actually bought
$40k price benefit
$10k setup cost

80,000 parts × $0.50 saved − $10,000 setup = $30,000.

See the working exampleHow much saving actually happened? — hypothetical examplePLAN100,000 parts × $0.50 = $50kopportunityACTUAL BUYING80,000 parts × $0.50 = $40kprice benefitADDED COST$10k one-time implementationcost this yearNET RESULT$40k − $10k = $30k net costbenefit

Match invoices and setup costs. Confirm profit and cash timing with finance.

Finance must confirm when it reaches P&L and cash. Parts still in inventory may affect timing.

Owner: Procurement and finance

Conceptual Digital & AI illustration
06 / Digital & AI / HYPOTHETICAL

Is the digital tool paying off?

Planners try shipment alerts to avoid expensive last-minute freight.

Expand one step, then remeasure
$40k/yearestimated net benefit
$60k/yearfull yearly cost
Pilot result checked
$100k/year freight benefit
$60k/year full cost

$100k benefit − $60k cost = $40k/year, estimated.

See the working exampleIs the digital tool paying off? — hypothetical exampleOPERATING CHANGEPlanners act on late-materialalerts each morningOBSERVED RESULTComparable test supports$100k/year less premium freightFULL ANNUAL COST$60k, including licenses,support and share of setup costsCHECKSame volume + service; financevalidates benefit; controls pass

Test at one more site. Recheck freight cost, delivery performance and use.

Annualized estimate: $100k − $60k. Recheck as volume and adoption change; avoid double-counting other projects.

Owner: Operating outcome owner

Conceptual Digital & AI illustration
07 / Digital & AI / HYPOTHETICAL

What can AI do without approval?

The AI writes an order for 200 units. The factory needs only 20.

Keep buyer approval before sending
20 unitsneeded
200 unitsAI draft: 10× too many
Buyer catches the error
Wrong units per pack
No automatic release

200 ÷ 20 = 10 times the quantity needed.

See the working exampleWhat can AI do without approval? — hypothetical exampleDRAFTAI suggests 200 units for anorder needing 20HUMAN CHECKBuyer catches a pack-size errorbefore sendingDECISIONAI may prepare orders; buyermust approve every releaseBEFORE MORE AUTHORITYFix unit checks; test limits,logging and stop controls

Fix the pack-size check. Keep buyer approval until controls are proven.

A plausible-looking order is not evidence that unattended buying is safe.

Owner: Business owner with technology and risk

Conceptual Cyber illustration
08 / Cyber / HYPOTHETICAL

What must we contain now?

Security confirms a stolen vendor account is connected to factory equipment.

Stop the unauthorized access now
Active nowunauthorized access
Factoryequipment affected
End unauthorized session
Check equipment safely
Verify before reconnecting

An intruder is connected now. Stop access safely, then check what was affected.

See the working exampleWhat must we contain now? — hypothetical exampleLIVE EXPOSURESecurity confirms anunauthorized active sessionFIRST ACTIONEnd the session; block the account;activate incident responseKEEP OPERATINGSecurity + operations isolateaccess safely; check affectedequipmentNEXTInvestigate, recover and verifybefore reconnecting

Security and operations end access safely. Check equipment before reconnecting.

Follow the incident plan. An unrelated test-system finding still gets an owner and deadline.

Owner: Security owner and affected business owner

Conceptual Cyber illustration
09 / Cyber / HYPOTHETICAL

What access does this job need?

A named technician needs eight hours to repair one robot.

Allow this repair, with limited access
1 cellrobot access only
8 hoursapproved window
One robot cell
Monitored session
Access ends with the job

One repair needs one robot cell—not permanent plant-wide access.

See the working exampleWhat access does this job need? — hypothetical exampleIDENTITYNamed technician; identity andapproval verifiedSCOPEOne robot cell through theapproved remote pathTIME + VISIBILITY8-hour window; session loggedand monitoredEND OF JOBAccess expires; verifydisconnection and revoke theaccount if no longer needed

Verify identity. Monitor the repair. Remove access when the job ends.

Grant only after required controls are verified. The job does not justify permanent plant-wide access.

Owner: Access owner with business sponsor

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