After several years of operation, the melting and ingot production workshop faced a critical decline in performance.
Decreasing production volumes, high material losses, and the erosion of operational know-how were threatening production capacity, quality standards, and overall competitiveness.
The organization reached a tipping point where the rapid industrialization of operations, performance management, and the strengthening of workforce capabilities became essential to restore growth and secure long-term profitability.
Accelerating & Cementing the Implementation of a Performance Operating Model
OPERATIONS & PLANNING
OPERATIONS & PLANNING
Redesign of planning and scheduling processes to restore flow and stabilize production.
Alignment of melting and ingot production operations with downstream manufacturing requirements.
Improved resource utilization through structured sequencing and load balancing.
ORGANIZATION & GOVERNANCE
Deployment of an agile organizational model focused on execution speed and accountability.
Clarification of roles and responsibilities across operations, maintenance, and performance management teams.
Strengthening of management routines to support daily decision-making and operational discipline.
PRODUCTION & PERFORMANCE MANAGEMENT
Design and deployment of a robust performance management system.
Definition and monitoring of key operational performance indicators.
Reduction of material losses through process stabilization and practice standardization.
Increase in production throughput while maintaining quality standards.
MAINTENANCE & EQUIPMENT PERFORMANCE
Redesign of the maintenance operating model to improve equipment reliability.
Implementation of new practices and tools to reduce unplanned downtime.
Improved coordination between production and maintenance teams to ensure operational stability.
INDUSTRY 4.0
Deployment of digital tools for real-time performance monitoring.
Integration of operational data to enable faster and more informed decision-making.
Introduction of Industry 4.0 solutions to sustain performance gains and support continuous improvement.