Mid-Size Producer Recovers $9,500/Month in Hidden Losses
$9,500/mo
Monthly Gain
The Situation
A concrete producer running 3 volumetric mixer trucks and averaging 500m³/month. On the surface, the business was profitable. Margins were consistent. No obvious problems.
What the Audit Found
⚠Over-ordering running at 11–13% per job — accepted as normal industry practice
⚠Average 2.8 hours of truck idle time per vehicle per day
⚠Dispatch sequencing creating 4–6 unnecessary repositioning trips weekly
⚠Two emergency orders per month at 18–22% surcharge premium
Before
Concrete waste %
12%
Truck utilization
63%
Emergency orders/mo
2–3
Cost per m³
$148
After
Concrete waste %
1.5%
Truck utilization
84%
Emergency orders/mo
0
Cost per m³
$124
Profit Recovery Breakdown
Waste reduction (12% → 1.5%)$4,800/mo
Idle time elimination$2,900/mo
Dispatch optimization$900/mo
Emergency surcharge elimination$900/mo
Total Monthly$9,500
