Material consumption framing
Verkor is a French company specialized in the production of high-performance lithium-ion battery cells for the electric vehicle market. Located in Dunkerque France, the gigafactory is part of the European dynamic of industrial sovereignty over batteries. It is part of the France 2030 plan and its valuation reaches several billion. It is therefore part of the very exclusive club of French unicorns.
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Customer request
In an industrial ramp-up phase, controlling material consumption is a central lever for profitability — all the more so in a sector where raw materials represent a preponderant part of production costs. To support its increase in demand, Verkor wanted to structure the monitoring of this consumption and equip itself with reliable management tools, connected to its IT environment.
Existing practices — declarations at the end of the shift, partial extractions, rotating inventories not yet reallocated by process — reflected an organization under construction, consistent with the plant's stage of development. The challenge was not to correct an error, but to anticipate: to lay the right foundations before operational complexity made the task more difficult.
Our mission covers four axes: audit the existing data ecosystem, build an analysis methodology shared between Finance, Supply Chain and Operations, develop associated management tools, and industrialize the whole to ensure its sustainability.
Results
On the structuring of the data, we established a complete map of material flows across all production units, identified the points of reconciliation between ERP and the reality on the ground, and established a methodology in three layers — theoretical consumption, declared consumption, real consumption — making it possible to align operational data and material accounting.
On the management tools, the Power BI dashboards developed cover yield monitoring, the analysis of inventory differences by financial impact, and the details of consumption by reference, by process and period. Each indicator is traceable and reconcilable with the ERP.
On automation, data pipelines have been fully automated with built-in controls in advance. A simulation module allows teams to project the financial impact of various production scenarios on unit costs.
This work provided the Finance and Operations teams with a robust management base, built to support the ramp-up of the factory over time.
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