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Context / Scope of project
The client’s copper tank house was based on older technologies and faced many challenges: low production rates, low current efficiency, persistent quality issues, and poor operator morale.
Client achieved:
- 80% improvement in “on-spec” loop production (essential to the elimination of cathode downfall
- 75% reduction in cathode downfall
- 33% increase in anode brushing frequency
- 25% improvement in starter sheets that met top tier quality requirements
- 8% increase in current efficiency
- 9% increase in production
- 50% increase in high grade quality production
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What we did:
- Developed shared understanding of the operational drivers of production
- Selected the six key drivers for focused daily attention
- Developed KPIs for key activities and published performance in the operator team rooms
- Improved the “wiring” to reinforce focus on the KPIs
- Established weekly Results-Actions-Reviews (RARs), to build accountability and responsibility
- Established the “visible factory” to build awareness and ownership for performance
- Increased the level of attention to Standard Operating Procedures across the six key activities that were linked to overall value creation
- Celebrated early success and continued to drive for improvements in performance
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