The Client operated a highly complex production and logistics network spanning 80 sites across Europe and the U.S., with performance varying significantly across the footprint. Many lines were operating more than 10% below industry benchmarks, limiting throughput on constrained assets and creating avoidable costs on underperforming lines. A scalable operating model was needed to rapidly improve performance, standardize execution, and unlock capacity without significant capital investment.
First Key partnered with the Client to design and deploy a scalable, data-driven operating model built for a network-wide application. Initial efforts focused on targeted Kaizen initiatives at individual sites to demonstrate value quickly and establish a repeatable framework for broader rollout. First Key applied line reviews, centerlining, V-curve analysis, and SMED to improve line performance and reduce changeover losses, while embedding DMAIC and Autonomous Maintenance to strengthen day-to-day execution and sustain gains. This structured approach aligned sites around a common improvement system while building internal capability to scale performance improvements consistently across the network.
The engagement delivered consistent, measurable improvements at both the site and network level:
• +5% improvement in OEE per Kaizen initiative
• >50% reduction in key changeover times, increasing line capacity, enabling additional volume without capital investment.
• Reduced waste and variability on underperforming lines, improving cost efficiency
• Scalable operating model deployed across an 80-site network, enabling sustained performance and EBITDA improvement
These improvements increased output on sold-out lines, reduced avoidable costs across the network, and established a repeatable system to sustain gains and drive long-term operational and financial performance.
