Boosting coating line performance and capacity for a global glass manufacturer
OUR CUSTOMER
THE CHALLENGE
Structurally low equipment effectiveness
The coating line operated at a consistently low TEEP level, directly limiting capacity, delivery reliability, and growth potential.
Recurring changeover and performance losses
Frequent changeovers, downtime, and quality losses reduced throughput and made line performance unpredictable.
Reactive maintenance and performance steering
Maintenance and performance management were predominantly reactive, with limited standardization and data-driven control.
Insufficient ownership and alignment
Processes, leadership routines, and behaviors were insufficiently aligned to structurally sustain performance improvements.
Building excellence together
The impact we made
- Structural TEEP (Total Effective Equipment Performance) improvement from ~26% towards 34%
- Capacity growth enabled towards 2.5-3.0 million m² of coated glass
- Reduced availability, performance, and quality losses through focused interventions
- A standardized, data‑driven operating model supporting future scaling and asset expansion
Facing Similar challenges?
OUR APPROACH in action
- Objective performance baseline:
Conducted a fact-based TEEP baseline and root-cause analysis as the starting point for prioritization and decision-making.
- Integrated transformation roadmap:
Developed a phased roadmap (2025-2027) balancing quick wins with structural, long-term improvements across assets, processes, and organization.
- Targeted improvement initiatives:
Focused on changeovers (SMED and mechanical improvements), availability (Pareto analysis and RCA), and performance & quality (debottlenecking and line balancing).
- Performance management system:
Implemented a standardized performance management framework (KPI’s, meeting structures, and reporting) to enable consistent, data-driven steering.
- Embedding ownership and capabilities:
Strengthened asset and maintenance processes, leadership routines, and competencies, with the client fully owning the transformation, supported by targeted hands-on expertise.
