Brief of Engagement One

• To reduce breakdown of critical machines from a level of 24 failures a month to as low as possible
• To identify weak areas that would not sustain the stress of running the facility to around 120% of its capacity

Results

• Failures reduced from 24 failures a month to 1 failure a year for the 36 identified critical machines.
• The plant runs at 129% of its designed capacity.

Brief of the Engagement Two

• Redesign the existing machine to obtain a productivity gain of around 50%; reduce maintenance time and effort; and build the machine locally at less than 10% of the price which would otherwise have to be paid if the machine is to be imported.

Result:

• All objectives of the engagement were achieved within 6 months of the start of the project.

Brief of Engagement One

To reduce the dangerously high levels of vibration (around 5000 microns) of Cement Mill to less than 1000 microns so that various product blends can be produced.

Results

• Vibrations reduced to around 500 microns.

Brief of the Engagement Two

• To improve plant availability from 289 days to 320 days within one year

Result:

• Plant availability improved to 330 days within one year.

Brief of Engagement One

• To increase yield of continuous pig casting machine to 97% from a level of 92 to 93%
• To decrease quality defects to zero
• To improve availability to 100% and functional accuracy to 100%

Results

• Yield increased to 98% plus in less than 5 months
• Quality defects reduced to almost zero in less than 12 months
• Percentage of poor pigs reduced by 70%
• Availability to 100% and functional accuracy to 100% within 9 months.

Brief of the Engagement Two

• To increase plant availability from 90% to 98% in two years’ time

Result:

• Plant availability improved to 98% in two years’ time

Brief of the engagement:

• To reduce the dangerous vibration of the refrigerant screw compressor from 28 mm/s to 2.5 mm/s

Result:

• Results achieved within three months after implementation of the solutions.

Brief of Engagement :

• How to increase the productivity by 2 times in 6 months time and then by 3 times in 1.5 years time

Results

• Productivity increased by 2 times within the first six months. By the ninth month productivity increased by 3 times.

Brief of Engagement

• Total organizational change - from Operational and functional strategy, structure, operational performance
• How to increase productivity by 3 times within three years
• Achieve a delivery commitment of 90% within one year

Results

• Productivity improved by 2 times in less than 8 months
• Delivery commitment has improved to 95% in less than 9 months time i.e. a delivery backlog from 11 months delay reduced to delivery within 17 days from placement of orders for 80% of the orders

Brief of Engagement

• Improve availability of machines from the present level of 80% to 100% in six months' time.
• Improve the function of the machine so that the quality of the output is within 6sigma

Results

• Availability increased to more than 100% in less than 6 months.
• A grinding machine relegated to rough finishing could now be used for final finishing and added 31 more gears to the total production. This could be achieved in less than 1 month's effort.
• Quality output is now within 6 sigma limit within 6 months for gear grinding machines.

Brief of Engagement

• To improve availability of Bliss Mill to 95% plus from the present level that varies between 80% to 90% and improve the productivity of the hundred year old mill by at least 10%

Results

• Availability rose to 95% in less than 6 months. Productivity increased by 25% and power consumption decreased by 17%