industrial

We know Industrial

Let us demonstrate with this case study.

Client

  • Major processing facility in Western Australia
  • Annual throughput of 12,000 BCM
  • Low-grade feed - highly variable metallurgy

Issues

  • High unit and manpower costs
  • FIFO logistics and accommodation needing significant upgrade
  • Need to improve output, plant availability, safe work and reliability

Key Methodology

  • McKinsey’s 7S theory extended with our own 7P methodology
  • Documented Work Process flows, Procedures and Protocols

Resolution

  • Three-level organisation hierarchy (management, team leaders, team members)
  • Shift handovers conducted at workstations
  • Reliability Centred Maintenance with planned mini shut downs a key feature of preventative maintenance
  • New teams formed: Operator/Maintainers, Maintainer/Logistics Personnel, Technical Planning Support
  • ‘Village Council’ formed to administer FIFO facilities

Plant reliability and availability trending at almost 100%

Outcomes benchmarked against similar facilities globally

  • Manpower at <50% of that required by competitor facilities
  • Costs  at <50% of that required by competitor facilities
  • Plant reliability and availability trending at almost 100%
  • Plant output consistently above guidance
  • Safety performance significantly improved - 1st quartile

Contact Maurice Driscoll Consulting and talk about the possibilities