PROJECT GOAL: 30% increase in Production
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
- Project goal locked in 30% increase of Production
PROJECT RESULT
in Production
+
0
%
Standardized and integrated processes created the foundation to operational stability & predictability.
Fundamentals of Industrial Manufacturing
- Complete redesign of business processes of planning & scheduling, maintenance excellence and shop floor execution ensuring better resources utilization resulting in higher operations efficiency
- Redesign of assignment’s workflow and daily targets for front-line supervisors with clear expectations
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