+51%
increase in gross margin
Project objective: Reduce COGS and cycle time, increase volume and raise gross margin
Results
Context and challenge
A unit for manufacturing, repairing and maintaining metal rolls for industries such as pulp & paper and textiles. The plant combined irregular demand and order-release delays with a fragile operational organization: no clear objectives, no labor KPIs, no standard-time baseline, reactive COGS control, Excel-based tools and misalignment between production and sales.
Approach and impact
Production volume
The plant’s first standard-time baseline; a daily performance meeting tracking deviations; a digital solution (mobile app, real-time production cockpit and dashboards) for short-interval control.
Integrated planning
A new planning and capacity-management process, with simulations; structured cycle-time management; reports and dashboards connected to the ERP, eliminating spreadsheets.
Cost of goods sold (COGS)
Real-time COGS control, hours, raw materials and unit cost vs. budget; an integrated routine correlating COGS, cycle time and status; optimization of labor, equipment and utilities.
*Selected project result. Gains vary depending on context, maturity and scope.