Driving Efficiency by Developing an Operational Management Model

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• Outdated and poorly maintained equipment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This case exemplifies how Falconi helped a steel and mining client move from inconsistent performance and outdated practices to a standardized, data-driven operational environment.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.

‍