CASE STUDY
Metal valuation and process governance improvement across 3 European plants through cross-functional assessment
Client Description
- Tier-2 electrical systems manufacturer supplying major OEMs
- Production in Germany, Switzerland, France
Key Challenges
- Lack of procedures, documentation and ERP integration for material valuation and tracking
- Manual Excel processes causing mis-valuations and data breaks
Approach
- Conducted end-to-end process mapping of metal flow from purchasing to finished goods
- Compared physical and ERP-tracked metal flows to identify loss and valuation gaps.
- Reviewed documents, conducted interviews, and validated/tested sample components to confirm data integrity.
- Developed dozens of hypotheses and validated multiple systemic risks in inventory and cost control
- Created cross-functional governance model with defined controls, approvals, and reporting cadence.
Results
- Verified no physical metal loss, but identified significant valuation risks due to manual processes.
- Delivered a transparent, unified metal value stream across all four plants.
- Established foundation for Lean Administration project to harmonize processes and enable future ERP integration.
Assessed 4 plants across Germany, Switzerland, and France to map full metal flow
Reviewed 73 documents, 19 interviews, and 17 samples to validate accuracy
Identified 5 systemic risks and 37 improvement hypotheses for process harmonization
