840%
ROI, with payback in 4 months*
Project objective: Structure an efficient operation, reduce non-quality and raise profitability
Results
Context and challenge
A textile company (monofilament yarns) owned by a Private Equity group. The global supply chain disruption raised demand and required a rapid increase in production output. Added to this were high waste levels from a lack of internal quality control and customer complaints that affected overall performance.
Approach and impact
Production and quality
An operating model to plan and monitor KPIs in real time and eliminate root causes: standardization of quality standards, daily and weekly non-quality management routines and agile fact-based decisions. Automated S&OP.
Planning and production
Increased output through capacity review and Master Scheduling by product and market; preventive maintenance and inspections; setup optimization with SMED and a sequencing matrix; automated planning with commercial SLAs.
Data and digitalization
Automated executive reports with dashboards connected to the ERP, eliminating Excel; ERP evolution to digitalize processes, with no paper controls or manual collection.
*Selected project result. Gains vary depending on context, maturity and scope.