Continuous Flow Operations

Case Study: Steel

Project Highlights

10 mills and NA headquarters

ROCE, EBITA, GDP, inventory reduction and CapEx goals

Machine reliability, yield, changeover, standard work

10 Op-Ex leaders & Rolling Resources to extend reach


RAW reduction


Faster changeover time


Fewer miles walked


Heat treat capacity gain


Project ROI

Optimize mill throughput to drive hard dollar benefits.

This high-production mini-mill steel producer and recycler was working in a traditional model of functional departments: planning and scheduling, operations, maintenance, warehouse and logistics, which could not deliver to the required levels of competitiveness. Kaufman Global was selected to deliver a program that effectively achieved tangible business results, drove organizational focus and alignment and entrenched internal Op-Ex capabilities.

Facility work optimized plant throughput by improving Overall Equipment Effectiveness, Equipment Reliability, Product Yield, equipment performance and changeover time. Internal capability was advanced through the formation and training of a Rolling Resources team. This team worked and traveled with Kaufman Global to speed a consistent deployment approach to continuous improvement throughout the sites while working to improve and integrate business processes linked between the mills and corporate functions.

“I came into this event thinking I would be walking out at lunch. From the very beginning on the first day I realized this was exactly what I was looking for. I can’t wait to participate in more Kaizen events.”

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Like These.

Real organization change requires fast action, fast impact and enduring confidence in their results. Put Kaufman Global to work for you.