The client, an aircrete block producer had experienced a gradual decline in product output over previous years and now needed to increase output levels in order to keep up with growing demand.
They introduced a multi-disciplined daily review process including Short Interval Controls at key process steps supported by ‘4C’ problem solving techniques.
Operator Led Maintenance routines were introduced to enhance engagement and ownership at operator level through greater anomaly identification and action planning.
Training and competency models were produced for all team leaders and team members.
Near hits were critically reviewed leading to re-assessment of factory safety ‘hot spots’.
Improvements to yard turnaround times were introduced.
QA procedures around mixer set up and raw material use were revised and improved.
Planned maintenance and it’s effects on downtime was optimised along ‘Planning’ and ‘Co-ordination’ themes.
Within 6 month and after a great deal of hard work all the key business metrics had either moved significantly towards or had achieved their targets.
A yield increase of 17k blocks per month (500 mixes) or 20 additional mixes per day was achieved. This was the equivalent of a 10% productivity uplift with a Full Year Effect value of £880k.