+33%
increase in production volume
Project objective: +25% in production volume
Results
Context and challenge
Extremely strong market demand for strategic products in the aerospace, nuclear and medical industries (“no plane flies without a product from this plant”). Urgency to accelerate ramp-up and restructure the Target Operating Model. Unclear productivity targets, poor data automation, underused capacity, managers and operators overloaded with administrative tasks (much non-value-added work, rework and high cycle time), integrated planning to improve and reactive leadership.
Approach and impact
Throughput and productivity
A single objective across planning and sequencing; weekly scheduling incorporating supply, backlog, machine performance and resources; performance management with a daily target per operator and systematic root-cause treatment; new leadership KPIs and data automation on the client’s Azure cloud; a new Target Operating Model.
Supervisor training and coaching
Training of all management in Active Management (+50% on average); a 13-week field coaching program with frontline supervisors, raising skills and performance culture.
Quality and waste elimination
Non-quality KPIs and action plans in daily and weekly meetings; identifying and reducing non-value-added activities, keeping the operator focused on producing defect-free.
*Selected project result. Gains vary depending on context, maturity and scope.