Client
Non-ferrous metal producer
Industry
Industrial manufacturing
Primary goal
Achieve record production performance
Make operations smarter
A leading non-ferrous metal producer with operations spanning a range of connected services was facing pressure to stabilize monthly production and achieve aggressive cost targets. Challenges in short-term planning, limited digital enablement, and sub optimal power optimization were affecting production consistency and cost performance.
KPMG in India was engaged to deliver a focused production improvement and cost reduction program — helping institutionalize agile execution, strengthen operational planning, and enable data-driven decision making across operations.
Client transformation journey
- Before
- During
- After
Fragmented operations limit production reliability
The client operated in a complex, asset‑intensive environment with multiple operational constraints.
Short‑term work planning and equipment scheduling inefficiencies caused production delays, while certain operations remained heavily reliant on operator experience without digital twin support. Power load balancing between renewable sources and captive power plants was ineffective, and the organization faced pressure to increase output while reducing operating costs. Existing execution models lacked the agility required to stabilize monthly production and cost performance.
The client engaged KPMG in India to help build a more integrated, data‑driven approach to improve production reliability and cost efficiency across the value chain.
Driving integrated operational and digital transformation
KPMG in India adopted a diagnostic and execution‑focused transformation approach, integrating operational excellence, digital solutions, and governance.
Operational diagnostics assessed production planning, utilization, and performance bottlenecks, identifying key constraints across a range of operations. Improvement levers were prioritized to support finished goods production stability and cost performance.
Targeted interventions across operations, maintenance, and reliability included Lean Manufacturing and Total Productive Maintenance (TPM) based initiatives to improve asset availability and utilization, along with structured production and maintenance planning to enable steady monthly output. Process discipline was embedded across operations to sustain improvements.
Digital enablement was introduced through a Digital Planning Tool for advanced planning and short-interval control, real-time dashboards using OSI PI, digital twins for key operations, and an Advanced Planning and Scheduling System (APASS) to better align operations and maintenance.
Additionally, cost reduction and power optimization levers were implemented, including digital tools to optimize power consumption, Captive Power Plant (CPP) flexibilization to improve renewable power absorption, and governance mechanisms to track initiatives and sustain benefits.
Delivering measurable production and cost gains
The program helped deliver tangible improvements across production and cost performance. Metal in concentrate increased, supporting the highest ever refined metals production, with an approximate 2 percent uplift.
Cost of production decreased by around 6 percent in dollar terms, driven by improved production planning, power optimization, and increased digital adoption across operations.
Enhanced planning and digital capabilities enabled better coordination across the value chain. Importantly, a sustainable execution backbone was embedded across operations, helping the organization maintain performance gains and support long-term reliability and cost efficiency.
How we make the difference
KPMG in India helped the client move beyond fragmented operations by establishing an integrated, data‑driven blueprint — aligning production planning, digital tools, power optimization, and governance across the value chain to enable more stable and cost‑efficient performance.
Please reach out to us to learn how we can support you in driving operational excellence and advancing your digital transformation journey.
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