The client
Large heavy-duty automotive parts manufacturer with end-to-end operations covering product development, engineering, casting, heat treating, forging and advanced machining (+2,000 people in scope).
Main challenges
- Operational inefficiencies and isolated workflows created and environment of strong pressure on service levels, lows margins and unsatisfactory productivity
- Unsettled and inconsistent business processes created misalignment on decision-making and unsuited shopfloor efficiency execution
- Reactive maintenance resulted in low equipment reliability, contributing to a firefighting mode and limited performance predictability
- Some data used, but not systematically nor in an integrated fashion – driving performance based on intuition rather performance metrics
- Need to redesign the organization structure to align it with a modern approach to operations management
Standardized and integrated processes created the foundation to operational stability & predictability.
Fundamentals of Industrial Manufacturing
RACIs with clear roles, responsibilities and ownership across planning, operations and maintenance
Individual annual performance metrics connected to daily execution with strong leadership oversight
People & Organizational Redesign
RACIs with clear roles, responsibilities and ownership across planning, operations and maintenance
Individual annual performance metrics connected to daily execution with strong leadership oversight
Integrated Performance Management Model
Automated daily & weekly data-driven metrics connecting performance and management routines
Target Operating Model fully deployed setting up a sustainability framework with audits embedded
The implementation of quick wins brought crucial operational results in the first couple of months, creating gradually a culture of higher performance across areas.
- 15% Increase in OEE for Critical Equipments
- 96% Production Plan Adherence
- 37% Scrap Reduction
- 200% Increase in Preventive Maintenance
Main Outcomes
Stabilizing operations, aligning functions, and unlocking sustainable performance through data-driven execution and integrated operating models.
- 35% Production Increase
- 97% OTIF Baseline 81%
- 21% Inventory Reduction
- +75% Reliability MTBF