Case study · Interim Management
Interim plant management at an industrial plastics processor
A medium-sized supplier to the plastics industry faced critical supply bottlenecks after the abrupt departure of its plant manager. At the same time, poorly coordinated process parameters on the extrusion and injection moulding machines led to increased scrap rates for demanding visible components. Within a few weeks, OEE (overall equipment effectiveness) had fallen below the economic minimum.
Immediate assumption of disciplinary and operational plant management on an interim basis. The priority goals were to fully secure customer deadlines, freeze the quality deviations and stabilise the processes of the entire shop floor within a fixed time window of six months.
Directly at the machines, barrel temperatures and cavity pressures were analysed systematically and a stable process window was fixed. To shorten changeover times, the SMED methodology was established directly on the lines with the remaining shift staff.
Incoming inspection of the raw polymers was supplemented with rapid rheological tests to isolate batch fluctuations before injection moulding. In parallel, a handover plan for the succession was developed with the owner.
Result
Delivery capability was stabilised at one hundred per cent from the second week of the mandate. The production-related scrap rate fell permanently thanks to the process corrections. After successful stabilisation, the area was handed over turnkey to a newly recruited internal successor.
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