Problem statement – Executive Director of an integrated steel plant was struggling with higher cost of production, variability in production due to various operational issues and dispirited workforce not tuned to current operational excellence practices.

Our Approach –

  1. Implemented reliability centered maintenance system
  2. Implemented world class management control system
  3. Designed organization goals based on balanced score card
  4. Implemented shutdown management system
  5. Statistical study of various parameters to control variations

Results –

  1. Reduction in conversion cost by 8%
  2. Reduction in downtime by 12%
  3. Improvement in production by 15%
  4. Reduction in shutdown days from 16 days to 12 days

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