+35%
increase in production
Project objective: 30% increase in production
Results
Context and challenge
A large manufacturer of heavy automotive parts, with end-to-end operations, development, engineering, casting, heat treatment, forging and advanced machining (+2,000 people in scope). Inefficiencies and siloed workflows pressured service level, margin and productivity; unstable processes, reactive maintenance and management driven more by intuition than metrics limited predictability.
Approach and impact
Industrial manufacturing fundamentals
Redesign of planning and scheduling processes, maintenance excellence and shop-floor execution; clear daily targets for frontline supervisors.
People and organizational redesign
RACIs with clear roles and ownership across planning, operations and maintenance; individual targets connected to daily execution, with leadership follow-up.
Integrated performance management
Automated daily and weekly metrics connected to management routines; Target Operating Model implemented, with built-in audits for sustainability.
*Selected project result. Gains vary depending on context, maturity and scope.