Plant Performance and Cost Savings


Plant performance turnaround, bolstering the bottom line by millions of dollars.


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A global manufacturer in the energy storage space was facing performance issues within its largest plant. It was operating well below plan. Process productivity was under 50 percent. Material costs were above plan. Its maintenance system had performance and compliance levels unacceptable to management.


A Patina leadership team assessed, developed processes, and built maintenance capabilities. Expertise ranged from engineering to purchasing and manufacturing leadership. Among the outcome, they identified critical tasks and activities, key tools, and summarized how the organization was addressing operations. They produced strategies and opportunities impacting management and compared current plans to validate work in process, as well as defined assumptions and quantified new opportunities.


As a result, successes and outcome included $3.8 million in material costs savings, a $3 million sustained reduction in working capital, 20% throughput improvement, and $500,000 in labor savings.

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