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Hawkin & Co Logo

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Tim Hawkin



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Hawkin and Co Logo

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)