Benchmarks & Client Cases
Production Efficiency in Process Industry
The Challenge
Problem
• Breakdown Maintenance losses of 14.7 hours/month
• Total duration of planned stoppages over the course of one year was 168.1 hours
• Average setup time of 74 min
• Quality losses of 9.15%
Root Causes
• Lack of information on unplanned stoppages and ad-hoc resolution of problems
• Performance losses due to lack of standard parameters for production
• Inefficient planned stoppages due to poor diagnosis, lack of resource allocation, material preparation and team coordination
• Micro-stoppages in paper transformation and undefined setup activities
• Suboptimal planning sequences
The Solution
• Structured Problem-Solving approach for unplanned stoppages, supported by detailed data
• Definition of optimal production parameters
• Standardised procedures and operators training
• More frequent planned stoppages managed through project management tools such as Last Planner, Risk Analysis and Task KANBAN
• Autonomous maintenance to reduce micro-stoppages during paper transformation
• Production sequencing guidelines and process standardisation to minimise setup activities
The Results
The project had a Payback period of 4 months with annual savings surpassing £1.7 million.
Breakdown
As a result of maintenance issues, breakdown times reduced by 20%
Planned Stoppages
Time for planned stoppages reduced by 26%
Quality losses
Volume of quality losses reduced by 4%
Setup Time
Logistics productivity increase by 31% with optimisation of layouts and containers
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