 |
 |
| Results
- Metal Smelter (2) |
| Context
/ scope of project: |
 |
ROE profile not ideal-
a keep / sell decision needed to be made |
|
Out-dated (plant built in 60’s)
technology making it difficult to compete |
|
Pot life among shortest in the industry |
| Client achieved: |
|
30% increase in casthouse
throughput |
|
$7.7 million reduction in costs |
|
$6 million reduction in WIP inventory |
|
$2 million reduction in scrap inventory |
|
40% reduction in number of products
produced monthly |
|
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What we did:
|
Value Driver Trees – “Where's the
money?” |
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Paretos - resource prioritisation |
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Contractor management |
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KPI alignment from GM to operator |
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Reviews – shift handovers, daily operations,
GM reviews |
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Lean manufacturing (e.g. 7 wastes, 5S, preventive maintenance) |
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Role clarity – ideal diaries |
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Workforce empowerment |
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Key process debottlenecking |
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Overtime reduction |
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Off-contract spend reduction |
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Inventory reduction |
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Process optimisation |
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Product rationalisation |
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Liquid metal logistics and scheduling |
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