Benchmarks & Client Cases
Accelerated Plant Shutdown
The Challenge
Problem
• Summer shutdown maintenance with many inefficiencies and a lack of standards
• High manpower costs (80 external resources)
• Long duration (3 weeks)
Root Causes
• Spares/tools not ordered in advance
• Critical Plan not visible
• Tasks planned with a lot of safety (buffer)
• Little time invested in task and resource planning
The Solution
• Pull Planning with Time and Cost Buffers
• Visual Management Boards for work and KPI monitoring
• Spare parts stored near machines, and tool/consumable kits prepared
• Daily cost control
The Results
The project resulted in Annual Savings of £2.5 million.
Manpower cost reduction
Manpower costs reduced by 25%
Shutdown duration
Shutdown duration reduced by 10%
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