+15%
increase in productivity
Project objective: +10% in productivity
Results
Context and challenge
A multi-site project in two countries: one plant needed to optimize resources and the other to increase capacity, both seeking higher profitability. Limited monitoring and control; planning and sequencing without constraint management, with replanning and low adherence; manual tools and reliance on spreadsheets; unclear agreements between Sales, Planning and Operations; overlapping responsibilities and overtime above benchmark.
Approach and impact
Governance and interfaces (RACI + stage gates)
A formalized RACI to eliminate overlaps; alignment of Sales and Operations through stage gates, production priorities and SLAs; an automated change flow in the S&OP.
Data and digitalization
A digitalization blueprint and systems integration into a BI platform, reducing Excel; automated reports and KPIs; digital visual management on the shop floor; integrated planning data for greater adherence.
Operational excellence
A revised and digitalized overtime authorization process; real-time performance monitoring; new daily shop-floor routines for more responsive decisions.
*Selected project result. Gains vary depending on context, maturity and scope.