Operational Excellence for Basic Metals and Metallurgy
Higher yield, fewer defects and lower energy per tonne. For steel, aluminium, rolling and extrusion plants in Greece, Cyprus and Europe.
- Material yield
- Energy per tonne
- Stable quality
Why operational excellence matters
In metallurgy, cost is decided by material yield, energy and equipment availability. Small improvements in scrap, changeover time and stoppages have a large effect on results.
Greece Lean Six Sigma helps plants link production data to losses, stabilise critical parameters and build daily management on the line.
Where we help
Material yield and scrap
Cutting losses, remelting, surface and dimensional defects.
Energy
Furnace consumption, holding times and heat losses.
Equipment availability
Stoppages, maintenance, OEE and failure analysis.
Schedule changes
SMED, size and alloy changes, production sequencing.
Quality and variation
SPC, process capability, MSA and root cause analysis.
Safety and 5S
Workplace organisation, standard work and visual management.
Common operational challenges
- Low material yield
- Surface defects
- High energy consumption
- Unplanned stoppages
- Long changeovers
- Variation in product properties
- Work in progress inventory
- Late deliveries
- Recurring customer complaints
- Differences between shifts
Our approach starts from the process, not from an off-the-shelf training course. We find where performance is lost, quantify the opportunity and choose the method that fits the problem.
From diagnosis to improvement
- Understand the processWe review flow, roles, data and controls.
- Set the baselineWe quantify performance with the right indicators.
- Find the dominant lossesWe focus on the problems with the biggest impact.
- Choose the right methodQuick win, Kaizen, root cause analysis, DMAIC or redesign.
- Sustain the resultWe build ownership, control, capability and daily management.
Typical performance indicators
Choose your starting point
Operational Excellence Diagnostic
Assessment of one process or value stream, with a prioritised map of improvement opportunities.
In-company training
A programme tailored to your sector, in a classroom or Live Online, with examples from your own operation.
Targeted improvement project
Lean Six Sigma applied to one specific problem, with a measurable result.
Related training
Frequently asked questions
Where are the biggest losses usually?
In material yield, energy and stoppages. A material balance and a stoppage analysis quickly show where the first improvement should focus.
Do we need a new data system?
Usually not. We start with the data already recorded and check its reliability with MSA before any analysis.
Do you always start with training?
No. We start from the process. First we find where time, quality or cost is lost and what it costs. Then we choose a quick win, Kaizen, a DMAIC project or team training.
Can the training run in-house?
Yes. Programmes run in-company, in a classroom or Live Online, with examples from your own operation.
Where do you work?
We work with organisations in Greece, Cyprus and Europe, in Greek or English.
Start from the process.
Find the opportunities. Quantify the losses. Prioritise the improvements.