Delivers a validated 33% increase in capacity along with a full CI implementation and Blue Print for roll out of “Lighthouse” concept to the BU.

Requirement

• Deliver a sustainable 20% (min) increase in batch chemical plant capacity prior to next high season period.
• Improve chemical plants ability to execute projects more quickly.

Challenge

• Time frame for analysis and implementation was very short, this negated the possibility of using any real CAPEX based approach. All increases would have to come from operational improvements.

Approach

• VOC/VOB and scoping assessment
• Hypothesis based study plan created and executed
• Detailed analysis to identify key areas for improvement,
• Full implementation plan with phased benefits profile.
• Milestone deliverables established and S2MS (steps to milestones) established every 10 weeks.
• 12 projects defined and launched. All led by Customer with E² Consultant as second chair.
• Leadership team fully trained. Black and Brown belts trained during project timeline. Every employee Yellow belt trained in local language (Swedish).
• Team met daily to manage SIC (Short interval control), weekly to review status by project area.
• Formal milestone reviews every 10 weeks.
• Full and active communications plan operational from day1 to both site and external stakeholder groups.

Results

• 33% validate increase in capacity (record output achieved during high season)
• Full CI capability developed and operational by end of project.
• Business Unit Director declared “ Best investment he’d ever made”
• Site heralded as best in class and a world wide showcase for the business.