This client decided to roll it’s optimisation programme across 10 of it’s asphalt plants. The timing of the roll out couldn’t have been timed any better, due to an area wide drop in demand of 17% diminishing dilution of expense and creating upward pressure of costs against budgets.
In order to achieve budget comfortably by year end the client would need to bridge an emerging £1.5m cost gap.
The client managed to spring board their approach to ‘Brilliant Basics’ through a 14 day focused plant roll out, split across 7 weeks in order to ensure the rate and pace of capability building didn’t leave team members behind at any stage.
All team members were involved in an industry specific simulation that highlighted the importance of ‘measure & review’.
Plant specific Performance Review Infrastructures were put in place ensuring Safety, Quality, Delivery, Cost and People measures were meaningful, reviewed regularly and action planned for improvement.
Asset Reliability and Performance was improved by using enhanced techniques for Plant Vulnerability & Criticality, Spares Assessment & Management, Condition Appraisal and Defect Reduction all supported by weekly maintenance Planning & Co-Ordination Reviews.
Material Waste & Giveaway was optimised through focussed ‘Batched vs Ticketed’ studies, material waste and giveaway analysis, and improvements to weekly quality reviews.
Leaders were coached for capability in Building High performing Teams through ‘Participative Management’ techniques.
Within a 12 month timeframe 70% of plants demonstrated a positive cost position vs the pervious years performance.
An overall benefit of £1.7m was achieved.