European Chemical Company

The Challenge:

• Old site operating at 20% of historical capacity
• Declining poor performance and engrained, poor safety and performance management behaviours
• Declining market share in some products facing fierce Asian competition with lower unit costs
• Lack of coordination between internal sales companies and manufacturing supply chain
• Inadequate Planning and Reporting with ineffective Execution Control Systems
• Limited use of Short Interval Controls, KPIs and Root Cause Analysis
• Very high levels of all types of inventory and low customer service levels
• Poor track record of delivering capital expenditure projec

What we did:

• Developed and installed robust planning, production scheduling and customer service processes
• Implemented an effective Execution Control System that introduced Short Interval Controls and KPIs with a focus on data driven performance
• Implementation of robust inventory, warehousing and logistics management processes and controls
• Established capital projects management and contractor management processes
• Delivered leadership and supervisory coaching to transform the performance management culture, focusing on achieving proactive safety and performance targets

The Benefits:

• Significantly higher levels of site performance (+44% increase in OTIF) and increased levels of management control and consistency
• Robust long, medium and short term production plans
• Significantly lower levels of inventory (38% reduction)
• More effective and confident leadership team
• Increased workforce productivity (+42%) utilised in a more cost effective manner
• Improved communication and coordination between departments with common goals and objectives
• Short interval controls installed on all critical processes
• Creation of a continuous improvement system & culture
• Successful co-ordination and execution of strategic capital projects (on time, within budget)