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Case Study.

Turnaround Program Management.

A company in the manufacturing sector was facing several high-priority issues that needed to be addressed simultaneously in order to stabilize operations and secure production release.

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The Challenge.

The company was confronted with a number of problems that significantly impaired the production process and management:

  • Production stop due to a failed cleaning validation
  • Low capacity and robustness of quality control (numerous deviations and residues)
  • Complicated structure of quality management
  • Low reliability and stability in the planning department
  • Many vacancies leading to a shortage of resources
  • No project management basis for coordinating the tasks

The Benefits.

  • Redesign of the release process: Increased efficiency by revising the entire release process and production documentation.
  • Quality control optimized: Reduction of unnecessary deviations through improved measurement procedures and reorganization of quality management.
  • Supply planning: Updating ERP master data, integrating relevant demand data and introducing a detailed planning tool.
  • Life Cycle Management: Establishment of a new department for life cycle management, capacity planning and support for open projects.

The Outcome.

Stable production within 10 months.

The company achieved stable production and consistent release, eliminating backlogs and production stops.

Reduction of deviations by 20%.

By optimizing quality control and improving measurement procedures, deviations have been significantly reduced.

50% faster approval processes.

The redesigned approval process has led to significantly faster and more efficient production.

The Result.

By implementing a comprehensive turnaround program management, the company was able to stabilize production, strengthen quality assurance and establish holistic planning and coordination across all departments.

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