Case Studies in Different Business Industries
Implement Global Operational Excellence Program Chemical Industry (Asia, Europe & North America)
Problem Statement:
Lack of global alignment on the continuous improvement approach, including a lack of monitoring systems to measure year over year performance improvements.
Methodology:
Conduct site visits to define the current state. Implement a monitoring system to track actual manufacturing costs and capacity utilization per product. Define site-specific and global initiatives.
Establish governance for the continuous improvement process.
Outcome:
Achieve 3% savings year over year.
Increase Overall Equipment Effectiveness (OEE) by 15%. Implement standard and actual costing systems. Initiate a continuous improvement process within maintenance and supply chain operations.
Leading Performance Indicators & Visual Performance Management Refractory Industry (Belgium)
Problem Statement:
The manufacturing performance was steered by over 40 performance indicators, including a lack of visual performance management on the shop floor.
Methodology:
Define leading indicators to drive performance, rather than lagging indicators. Transform leading indicators into objectives that are monitored and displayed on the shop floor. Involve all stakeholders to ensure successful implementation. Link rewarding to "real" performance indicators driving the business performance.
Outcome:
Employees gained a clearer understanding of how their performance affected the business. Real-time performance monitoring enabled stakeholders to immediately grasp performance upon entering a manufacturing area. Achieved a 20% increase in throughput.
Enhanced the relationship between employees and the employer.
Implementation of Manufacturing Excellence Journey within Chemical Industry (Asia, Europe, North & South America)
Problem Statement:
20 manufacturing sites are operating within a regional organizational structure with a lack of focus on operational efficiency and continuous improvement.
Methodology:
A high-level assessment was conducted to select sites on each continent to begin a continuous improvement journey. An analysis of operational activities impacting cash flow and P&L was performed. A Manufacturing Excellence framework was defined, based on several operational excellence pillars specific to the company.
Outcome:
Local and global opportunities were identified in cooperation with the various sites.
Initiatives and financial potentials were outlined, including the process of sharing best practices.
Software was implemented to monitor the status of the various initiatives. Global key performance indicators were defined and implemented to guide global manufacturing performance.
The most crucial part was the transition process to alter the company's mindset towards applying continuous improvement sustainably.
Other Cases? Challenges? Opportunities?
Please reach out to us if you wish to discuss a particular case related to your company, or if you're interested in learning more about the cases we have handled.