01

Case study · PRV-011

On-time delivery raised from 81% to 97% across three plants

One planning rhythm across three plants, with constraint-based scheduling at the bottleneck line.

Client

Industrial components manufacturer

$220M revenue · 3 plants

Industry

Manufacturing

Service

Operational Excellence

Length

16 weeks

Year

2025

Statement of result · On-time delivery

Sample data

Before

81%

+16 pts

After

97%

Change

+16 pts

Relative

+19.8%

Timeline

16 weeks

Baseline 81

Source

Plant MES data, 8-week rolling averages.

Workers on a factory production line

Fig. · Client site — Industrial components manufacturer

Sample image

Workers on a factory production line

Fig. · Client site — Industrial components manufacturer

Sample image

01 · The question

Three plants make the same components. Why does one deliver on time and the other two don't?

02 · What we found

—

—

The bottleneck line was scheduled like every other line, so it ran out of work twice a week.

The bottleneck line was scheduled like every other line, so it ran out of work twice a week.

—

—

Each plant planned on a different horizon and released orders on different days.

Each plant planned on a different horizon and released orders on different days.

—

—

Expediting consumed planners' time and disrupted the schedule it was meant to protect.

Expediting consumed planners' time and disrupted the schedule it was meant to protect.

03 · What we did

We installed one weekly planning rhythm across all three plants, scheduled the bottleneck first and protected it with a buffer, and replaced expediting with a daily constraint review.

Deliverable · Constraint schedule

Sample · PRV-011

Constraint schedule

Measure

Result

Result

Note

Bottleneck utilisation

Bottleneck utilisation

92%

92%

From 74%

From 74%

Orders expedited

Orders expedited

4%

4%

From 15%

From 15%

On-time delivery

On-time delivery

97%

97%

8-week average

8-week average

Industrial components manufacturer

Operational Excellence ·

2025

04 · What happened

On-time delivery rose from 81% to 97% in 16 weeks, measured on 8-week rolling averages from plant MES data.

Before

81%

+16 pts

After

97%

Before

81%

After

97%

Timeline

16 weeks

Source

Plant MES data, 8-week rolling averages.

Illustrative sample data. Provan, its people, clients, figures and sources are fictional and shown for demonstration only.

04

Next step

Facing something similar?

Talk to Tomás.

Tomás Rivera leads Operational Excellence. A 30-minute call is enough to tell whether a result like this is within reach for you.

Book a call

View Operational Excellence

Your request

≤ 1 working day

A partner replies

We’ll respond within one working day.

04

Next step

Facing something similar?

Talk to Tomás.

Tomás Rivera leads Operational Excellence. A 30-minute call is enough to tell whether a result like this is within reach for you.

Book a call

View Operational Excellence

Your request

≤ 1 working day

A partner replies

We’ll respond within one working day.

04

Next step

Facing something similar?

Talk to Tomás.

Tomás Rivera leads Operational Excellence. A 30-minute call is enough to tell whether a result like this is within reach for you.

Book a call

View Operational Excellence

Your request

≤ 1 working day

A partner replies

We’ll respond within one working day.

Create a free website with Framer, the website builder loved by startups, designers and agencies.