Interim Management

Upgrading the automation & control systems of an Italian engineering company.

The problem

The client is an engineering company specializing in the production of automotive components using iron castings. It is part of a multinational Spanish automotive group. 

Despite boasting production levels that make it a benchmark for other companies in the group, the company finds it needs to modernize its plant to be able to control production parameters in real time. The parent company decides to start the modernization process by upgrading the control systems of two main lines. The window for execution is limited to five weeks. 

The challenge

During this tight timescale, the following activities have to be carried out: removal of the existing equipment and cabling of the old system; installation of new cabling; testing and checking of connections; start-up of the new control system and calibration of the operating cycles; training of plant supervisors on the use of the new systems. 

The plant has to resume production by the established date because customers need to receive components to feed their own production lines. 

On top of deadline constraints, there are all the unforeseen events that may occur when a new system is installed on cabling that has been in place for many years.

The Solution

The complexity of the operation calls for the intervention of a senior project manager. Contract Manager rapidly identifies and provides one. 

The work is completed within the set deadline, despite countless difficulties arising from inaccuracies in the old wiring diagrams.

The success of the assignment lies also in the fact that production returns to pre-closure levels less than ten days from resumption of production, much to the satisfaction of the client company and its customers. Three months from the end of the assignment, the OEE of the upgraded lines reaches 85%. 

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