From custom production to mass production
A medium-sized company working in defense industry faced the need to transform
its production model, shifting from small-batch, custom manufacturing to mass production.
The main challenge was to build two new production facilities from scratch and to re-engineer
two existing plants, streamlining current processes and developing new integrated workflows
while maintaining high standards of quality, safety, and operational efficiency.
From custom production to mass production
A medium-sized company working in defense industry faced the need to transform its production model, shifting from small-batch, custom manufacturing to mass production. The main challenge was to build two new production facilities from scratch and to re-engineer two existing plants, streamlining current processes and developing new integrated workflows while maintaining high standards of quality, safety, and operational efficiency.
Solution
The company entrusted the entire transformation process to an EPC-M (Engineering, Procurement, Construction Manager) for the new facilities and the refurbishing of existing processes. Preventive and proactive tools were introduced in maintenance, quality, safety, and strategic planning to achieve robust and reliable outcomes. Special emphasis was placed on managing internal interfaces within the company, external partners, and institutional stakeholders at the European level to ensure efficient vertical integration and a smooth transition.
Achievement
The transformation from small-batch production to mass production has been successfully completed, with two new greenfield plants now operational and two brownfield facilities optimized. The adoption of advanced tools for quality, safety, and maintenance management has led to a significant improvement in operational performance and greater reliability of processes. The company has strengthened its production capacity, enhancing efficiency and reducing risk of raw material shortages.