The project aimed to create a new operational model for a production and logistics network spanning 80 sites across Europe and the US, establishing a foundation for operational excellence. First Key focused on developing and deploying operational excellence tools, initially implemented as Kaizen projects within individual sites, demonstrating their value and standardizing their future redeployment. The operational model, developed over several months, addressed lines running over 10% below industry standards by implementing approaches such as line reviews, center lining, V curve analysis, and single-minute exchange of die (SMED) for rapid changeovers. Lean tools like define, measure, analyze, improve, control (DMAIC), SMED, and Autonomous Maintenance were used, resulting in each Kaizen project delivering at least a 5% improvement in Overall Equipment Effectiveness (OEE) and SMED projects reducing key changeover times by more than 50%. The project achieved productivity gains by enabling volume growth on sold-out lines, impacting EBITDA, and achieving significant savings through OEE improvements on non-sold-out lines, establishing a scalable model for sustained operational excellence across the network.
