Improving the production plan implementation by 15%
on key lines thanks to better planning and daily performance reviews.
What was achieved?
20% reduction in defects and corrections
Leading to a direct increase in the effectiveness of the OEE process.
Higher predictability of the plant operation
clearer rules for planning changes, staffing positions and responding to deviations from the plan.
Better cooperation with customers
structured reporting and regular reviews of parameters with customers have resulted in more transparency and trust.
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Project challenges
The plant operated in an environment with high-quality and deadline requirements, typical of cooperation with OEMs in the automotive industry. The growing number of orders, intense production rhythm and high dynamics of changes in the area of employment required additional reinforcement at the plant management level. The company decided to use the support from an experienced Interim Plant Manager who brought a fresh perspective and practical experience from other factories and helped organise day-to-day production management and cooperation with key customers.
High requirements of OEM customers
the necessity of maintaining stable quality parameters and timely deliveries despite high order volatility.
Complex production environment
multiple production lines and processes requiring a consistent approach to planning, supervision and reporting of results.
High dynamics of resources
the need to strengthen the role of leaders and streamline basic work standards on the production floor.
Targets set
Stabilising the plant operation
ensuring predictable implementation of production plans while maintaining quality requirements.
Intensifying cooperation with OEM customers
streamlining communication and reporting to key recipients.
Improving the organisation of production
identification and implementation of improvements in the area of planning, supervision and production accounting.
Strengthening the team
building a stronger leadership role and higher employee engagement in achieving operational goals.
Solutions implemented
Daily rhythm of production management
introducing short operational meetings with a clear overview of the plan, results and priorities for change.
Organisation of indicators
definition of key KPIs for the plant (productivity, quality, timeliness) and regular monitoring of their implementation.
Strengthening the role of leaders
clarifying the responsibilities of foremen and line leaders and supporting them in the day-to-day management of their teams.
Improving cooperation with customers
streamlining reporting for OEMs, establishing clear points of contact and conducting regular reviews of project and delivery status.
Client
Redegate’s client was an international automotive company manufacturing components for leading vehicle manufacturers. The plant located in Poland is an important link in the supply chain, serving several demanding OEM partners. After years of neglect, the plant was at risk of losing its most important projects and orders from leading customers.
Expert’s role and experience
Interim Plant Manager
The expert took responsibility for the daily management of the production plant, focusing on stabilising the implementation of plans, improving quality indicators and coordinating activities between production, quality, maintenance and logistics better. They worked with management and OEM customer representatives to ensure that daily operational decisions were consistent with business expectations.
Many years of experience in managing production facilities in the automotive and related industrial sectors.
Practical experience in conducting production stabilisation and development projects, with an emphasis on quality, timeliness and operational efficiency.
Experience in working with OEM customers, including building transparent communication, reporting results and implementing mutually agreed work standards.
