+26%
increase in performance
Project objective: +20% in performance
Results
Context and challenge
Installed capacity underused against growing demand. Predominantly corrective maintenance and availability below target, with a barely used CMMS. Low equipment efficiency, no integrated performance management model; almost no digitalization (heavy use of paper and manual Excel spreadsheets). Production had no tools to manage weekly and monthly capacity plans, and the lack of service-level agreements with the commercial side led to frequent replanning.
Approach and impact
Planning, sequencing and interfaces
Interface agreements with the commercial side reduced changes due to urgencies and priorities by 77%; new KPIs and management tools.
Operational excellence
A more analytical and digital culture; procedure review and Lean Six Sigma (-12% in setups); tablets for automatic downtime reporting and real-time analysis; IoT with sensor streaming, the end of paper and Excel.
Maintenance excellence
Restructuring of planning and digitalization via CMMS (over 90% adherence); an advanced data platform connecting IT, with AI for predictive failure analysis and resource optimization.
*Selected project result. Gains vary depending on context, maturity and scope.