The key objective in manufacturing is to get the right raw materials or parts to the right machines at the right time. Too fast or too soon creates excess in-process inventory. The result, in many cases, is a poor use of capital, in the form of excess in-process inventory and/or under-utilization of equipment.

In any single calendar year, there are 8760 hours available for the manufacturing operation, as can be seen in the figure below. Statistics have shown that about 44% of the total time available is lost due to incomplete use of second and third shifts. The skilled, experienced people required to operate and setup machines are either not available or disinterested in working "unsocial" hours, and the problem is going to get worse.

34% of the total time is lost due to vacations and holidays. 12% is lost while machines are being loaded or unloaded. About 4% of the time is lost due to process difficulties or unforeseen material, tooling, or quality-control problems. This leaves only 6% of the total time for actual production. The batch manufacturer's capital investment for equipment and facilities is working, trying to pay for itself, less than one hour in seventeen. This high inefficiency indicates the need for an FMS.