When operational performance starts to slip, the root causes are rarely isolated. Low OEE, unplanned downtime, inventory shortages, maintenance gaps and workforce challenges often reinforce one another, creating a cycle that’s hard to break without a structured, end-to-end approach.
This was exactly the situation one manufacturing customer faced when two senior project managers from KCG stepped in to lead a comprehensive operations restructuring initiative.
The Challenge
Production efficiency was critically low, driven by frequent unplanned downtime in Assembly and Welding. Capacity transparency was missing, production planning adherence was unreliable, and inventory levels of WIP and finished goods were close to zero. On top of that, packaging shortages, weak maintenance adherence, high absenteeism, and untrained operators further strained daily operations.
The KCG Approach
Our project managers conducted a 360-degree operational assessment, addressing production, maintenance, capacity, inventor and HR as one integrated system. Using proven methodologies such as RCA and PDCA, the team focused on sustainable improvements rather than quick fixes.
Key actions included:
- Full capacity analysis of dedicated and shared machines and cells
- Targeted PDCA cycles for production and maintenance across all technologies
- Clear headcount, fluctuation, and absenteeism targets benchmarked against the market
- Structured training plans with transparency at every machine and station
- Defined KPIs across five work packages, tracked daily and reviewed with immediate countermeasures
- Weekly management reviews to ensure momentum and accountability
The Results
The impact was both rapid and measurable:
- OEE improvement of +12% in Assembly and +20% in Welding
- Production planning adherence increased from 81.6% to 99.8%
- Finished goods inventory improved by +53%, WIP by +52%
- Full capacity transparency and utilization achieved in Welding cells
- Maintenance processes stabilized with clear KPIs across technologies
- Targeted action plans implemented to reduce absenteeism and stabilize key operational roles
Why It Matters
This project demonstrates how a structured, data-driven approach, combined with experienced leadership, can quickly restore control, transparency and performance in complex manufacturing environments.