8 Oct · 7 minutes min
Driving Efficiency by Developing an Operational Management Model
Henrique Melillo
11+ years of global experience
The Client & Challenge
A Global Steel & Mining company with plants across North America was experiencing:
- Highly variable performance between facilities
- Outdated and poorly maintained equipment
- A lack of standard operating procedures and result-tracking mechanisms
The organization lacked a systematic framework for consistent execution and governance.
Opportunity:
Develop and implement a robust operational management model to stabilize and improve performance.
Project Approach
Falconi executed a four-phase model, driving alignment from leadership through to operational execution:
1. Management for Results Training
- Delivered theoretical and practical training for all supervisors
- Trained 140+ managers on Falconi’s performance-driven methodology
2. Process Control
- Mapped and prioritized key operational processes
- Identified critical tasks and defined KPIs linked to business outcomes
- Launched anomaly treatment routines
- Defined and tracked 65 improvement actions from data-driven diagnostics
3. Standardization Program
- Developed 12 key task standards
- Delivered on-the-job training for operators on new standards
- Implemented a system to verify standard execution in the field
4. Handover & Governance
- Provided coaching for sustainable standardization
- Supported execution of RACI matrix, governance routines, and continuous support
Results Achieved
Metric 2019 2020 Change
Availability 37.5% 47.8% +10.3 p.p.
Performance 74.9% 78.3% +3.4 p.p.
Quality 41.2% 49.2% +8.0 p.p.
OEE 11.6% 18.4% +6.8 p.p.
Standards Adherence — — +45%
✅ Total OEE improvement of 16.8 percentage points(58%)
✅ Significant boost in adherence to standardized procedures
Why It Worked
- Ground-up alignment from supervisors to operators
- Heavy emphasis on training, ownership, and performance tracking
- Fast and structured standardization of high-impact processes
Conclusion
This case exemplifies how Falconi helped a steel and mining client move from inconsistent performance and outdated practices to a standardized, data-driven operational environment. The transformation led to major gains in OEE and process reliability, supported by a scalable management model that ensures continued performance evolution.
Insights