Our client is a manufacturer of high quality branded specialist polyester fibers and filament yarn for the home textiles, automotive and apparel industries, and for technical applications.

The company operates 2 production sites, employing more than 1,000 people.

High fixed costs significantly impact results caused by changes of production planning. The highly fragmented maintenance operations were a result of a historic business growth.

• Assessment of the current maintenance operations
• Design of a state-of-the-art maintenance process and organisation
• Digitalize the maintenance operations
• Achieve sustainable reduction in maintenance costs by:
  – Reduction in labour costs / 3rd party costs
  – Reduction in material costs

We followed a two-stage process.

Stage 1: Assessment

• The assessment included detailed analysis of all 27 maintenance departments including manning level and, processes. Syngroup carried out detailed line observations to understand how labour was deployed and utilised.

Stage 2: Recommendations and Implementation

• The highly fragmented maintenance operation needed a complete re-design of the organisation and its processes.
• During this stage the new organization and new processes were jointly developed. Syngroup assisted as a sparring partner in staffing of the organisation and alignment with the workers council.

• LEAN
• Organisational restructuring
• Manning Optimisation
• System re-design