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 Results - Turnaround of recycled fibre plant

Context / scope of project : This Greenfield technology had been in place for 3 years, have never reached full capacity and was plagued with quality problems which in turn were harming other sites within this division. Our brief was to fix this quality problem, reduce costs, improve availability and throughput and return the site to profit.

Client achieved:
EBITDA increased from $0m to $12m
Production up by 31%
Variable cost down 22%

Total downtime reduced from 11 to 4 hrs/wk

Renegotiated wastepaper prices down $5.4m

14% reduction in dirt

Average payback on initiatives <4 weeks
Overcame technical and quality constraints to enable 300% increase in usage by downstream mills

Successful sale after 15 months



   
   
     

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What we did:

Value Driver Trees – “Where’s the money?”
Debottlenecking – controlled experiments, Statistical Process Control
Process optimization and modification
Variability reduction
Systematic elimination of quality issues
Product recipe
Cost reduction – chemicals, energy, waste paper, repeat maintenance failures
Reviews – morning meetings, shift handovers, weekly cascaded reviews
Maintenance planning


 
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