Our client is a leading industrial company, operating across the entire metal processing chain: batch composition, melting and remelting and machining high-value-added components for the aerospace and naval sectors.
The workshop dedicated to melting and producing metal lots —crucial for subsequent manufacturing steps—is experiencing a decline in performance. The main challenges identified include a significant drop in production volumes, major material losses, and a loss of internal expertise.
In an increasingly competitive environment, this situation has become critical. It is therefore essential to quickly restore the workshop’s production capacity while maintaining the required quality standards, to ensure client satisfaction and loyalty.
The objective set is clear and ambitious: within 8 weeks, halt the decline in performance, eliminate quality defects, and increase output by at least 10%.
Accelerating & Cementing the Implementation of a Performance Operating Model
Planning & scheduling Optimization
A complete overhaul of each process, ensuring better flow and resource utilization maximization.
Deployment of an agile organizational model
Implementation of a new organization focused on speed of execution and target realization
Activation of enhanced performance management
Introduction of innovative tools and targeted support to foster active management and team engagement.
Redesign of Maintenance operating model
Review of all processes, best practices and tools in order to improve the maintenance performance: ex equipment reliability, reduction of production interruptions.
Integration of Industry 4.0 tools
Adoption of advanced digital solutions allowing real-time performance tracking allowing fast & informed decision from the management.
In just 8 weeks, Magellan’s intervention produced tangible and measurable results. Overall performance saw a significant improvement:
• Overall Production increased by 20% (initial target was 10%)
• New records were set on all the 4 key indicators compared to previous years
o Unit Production +44% over 1 year
o Tons +23 % over 1 year
o Production order + 86%
o Team effectiveness + 120 %
Those results were achieved with a much smaller team than the previous years. Those performances demonstrate Magellan’s approach effectiveness to optimized results & set a positive and sustainable dynamic.