Business challenge
Our client had seen its top and bottom-line financial performance structurally decline and management had articulated a clear ambition to improve. This required a major transformation in end-to-end Operational Excellence maturity addressing inefficiencies and different ways of working. A step change in behavior at all levels was necessary, leading to a new way of working resulting in cost control and improved results.
Process
The ambition to improve was translated into an Operational Strategy and a transformation plan that would deliver on the improvement targets that were defined. 3 Main workstreams to address the challenges were established
- Planning & Production
- Maintenance and Cleaning
- Material Management and Quality
Operational Strategy and Transformation
Having an operational strategy does not mean much if it has not been translated into a clear plan of action to reach the strategic targets set. This includes a transformation plan as the catalyst for change always lies in the human resources involved in the realization of the plan. A step change in behavior at all levels was necessary, leading to a new way of working resulting in cost control and improved results. Finally a management system was developed to support the transformation program with clear visual feedback to maintain the gain.
Program and Performance Management
In just a few weeks, we jointly developed a complete integrated management system in order to have all departments involved quickly.
Standardized Performance Management was achieved though design and implementation of best practice processes with clear KPI’s. A structured management and reporting system was implemented to make sure that all stakeholders would speak the same language when discussing results and performance
Asset Life Cycle Management
The teams designed and implemented better ways to conduct short technical stops and focused on preventive and planned maintenance to improve up-time of the production facility.
Variable Cost Optimization
By working on improved Planning and Production processes (with a broader view) there were immediate efficiency improvements in the entire process from planning to production to packaging.
Soft results
The new organizational structure with continuous improvement focus and supported by clear performance KPI’s resulting in a working culture where people make the difference on a daily basis.