Case Study
Maintenance Optimization
16% Reduction in manning levels
€1M annualised bottom-line savings
State-of-the-art maintenance structure
Service line
Business Transformation: Operations
6 months
Syngroup Office
Maintenance Optimization
Polyester Fibers & Filament Yarns

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
Focus area
Organisation and process re-design
System selection & implementation
Our Approach

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.
Direct benefits of €1M annualised
Transformation to a centralized maintenance organisation to balance demand peaks within the plant compared to within the department
Increased transparency of maintenance costs
Usage of mobile devices for work distribution and reporting
Implementation of inventory management for spare parts leading to a reduction in working capital and material costs
16% reduction of work force
  • LEAN
  • Organisational restructuring
  • Manning Optimisation
  • System re-design