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 Results - Turnaround of integrated metals manufacturer

Context / scope of project : This producer had outdated technology, was at the far right of the cost curve, faced significant community pressure because of high emissions of potentially harmful metals into an urban community and large stockpiles of potentially harmful waste on site. Its workforce had faced the threat of closure as far back as people could remember and they were immune to calls for a need to change. They had also pulled all the easy levers years ago and had run out of ideas. PIP’s brief was to deliver a turnaround in performance and ensure these results were sustainable.

Client achieved:
Cumulative EBIT benefit of $26m
Annualised improvement of $34m/year
Cost/tonne down 28%

Production up 34% ($13mpa)

Feed mix profit up $3mpa
Recovery up $7mpa
Reduced environmental emissions by 50%
75% of results delivered in 6 months

Average payback on initiatives of 6 weeks



   
   
     

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What we did:

Value Driver Trees – “Where’s the money?”

CPR – Critical Path Reduction for planned shuts, Extended Campaign Length, Planned Shut Management Processes and Skills

Systematic elimination of root causes of maintenance failures
Debottlenecking
Waste elimination – mass balance, pareto of opportunities, root cause elimination
Emission reduction
Raw Material Optimisation
Contractor Management
Procurement
Cross site material optimization
Accountabilities, role clarity, reviews
Skills matrix
Operator accountability
Supervisor training


 
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