Industrial maintenance provider wanted to implement improvements to deliver best in class service
Our client is a professional organization with extensive experience in the process industry in site and manufacturing services. The process industry is a challenging work environment, where the focus is on safe and optimal production for their clients.
Maintenance of industrial plant takes exceptional planning and execution. In order to provide a better service to existing clients and to be able to take on more business without any capital expenditure they requested simple process flow analysis including information and material flow and material availability and handling. They also wanted to educate key personnel in the various tools and techniques of Lean in order that they could continue the continuous improvement without the help of external consultant experts.
How we helped
We agreed a plan to provide numerous 1 week workshops on specific planning activities, material preparations and workflow. Current processes were mapped and extensive expenditure analysis was carried out to establish labour and material overspending. The output of this analysis was then used to plan future workshops which were supported to completion.
Projects executed included the following types of activity:
- Reduced Planned Maintenance preparation costs (Labour and Material) for the correction for corrosion under insulation, correction for installing and maintaining temporary clamping and correction for replacement of pre-fabricated pipe sections
- Mechanical maintenance workshops using simple good housekeeping techniques provided for a safer work environment, quick and easy access to regularly used tools and equipment
- Electrical maintenance workshops were used to gather and store left over parts from previous work orders. Results increased Hands On Tool Time and located previously unknown available parts in excess of 150k Euros thus enabling them to provide a less expensive service to their clients
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