We would like to use cookies to ensure we give you the best experience on our website. If you consent to us using cookies, please click on the tick.

Skip to main content
Hawkin & Co Logo

Lets work
with each other.

Consulting

Tim Hawkin

CEO

tim@hawkinandco.com

Tell us about your business

You must accept cookies to fill out the contact form and send an enquiry.

Hawkin and Co Logo
Share:

The Challenge:

  • 100+ year old site with inconsistent performance and engrained, poor safety, supervisory and performance behaviours
  • Declining market share in some products facing fierce Asian competition with lower unit costs
  • Lack of flexibility in a highly unionised workforce with low levels of responsibilities and accountability, especially in areas requiring continuous improvement
  • Lack of coordination between highly interdependent production plants, support services (waste and energy) and engineering
  • Inadequate Planning and Reporting with an ineffective Execution Control Systems
  • Limited use of Short Interval Controls, KPIs and Root Cause Analysis
  • Little control over the usage and cost of: raw materials, contractors, overtime and energy consumption and costs

What we did:

  • Implemented a new workforce model with a shift performance management system
  • Implemented a more effective Execution Control System that included introducing greater SICs and reporting KPIs on a shift / daily basis with a focus on data driven performance
  • Implementation of lubrication program, bad actor process; RCFA process; Criticality index / asset care strategies & PM prioritisation
  • Contractor jobs included in work order system and established contractor management process
  • Implemented RACIs on waste & energy management and trained workforce on energy & waste awareness

The benefits:

  • Higher levels of consistent performance, allowing the site to more than double production volumes within 12 months and consolidate production from another site
  • Increased levels of management control and consistency
  • 15% increase in labour efficiency & improved labour flexibility to allow for safe reallocation of resources in a more cost effective manner
  • Improved communication and coordination between departments with common goals and objectives
  • Short interval controls installed on 18 plants measuring the performance critical processes
  • Creation of a continuous improvement system & culture
  • Savings on: overtime £0.2m, raw materials £0.5m, waste £0.2m, energy £0.2m and contractors £0.3m
Back