At one of their mature sites, our client was facing increasing safety and integrity risks
The Situation
At one of their mature sites, our client was facing increasing safety and integrity risks, also identified some engrained, poor safety, supervisory and performance behaviours that were not in line with corporate standards. Highly unionised and overmanned workforce demonstrated lack of flexibility, which resulted in low levels of responsibilities and accountability, especially in areas requiring continuous improvement. Moreover, our client was in need to address the processes of inadequate planning and reporting with an ineffective Execution Control Systems that was not data driven, while at the same time there were issues with little control over contractors, quality change controls and deviations, and inventory levels. Last but not least, the client identified that the regularity of quality testing was too great and perceived as a policing body rather than an enabler.
Approach
The safety of our clients is, and always has been, our highest priority. Advisian partnered with the client to complete the following processes:
- Implement a new workforce model with a shift performance management system;
- Implement an effective Execution Control System that introduced Short Interval Controls and KPIs with a focus on data driven performance;
- Implement criticality index/asset care strategies, PM prioritisation, lubrication program, bad actor process and RCFA process;
- Establish contractor management process, including Contractor jobs in work order system;
- Redefine roles and responsibilities and train workforce on energy and waste awareness.
Results
As a result of changes, the following outcomes were achieved:
- Higher levels of site performance and increased levels of management control and consistency;
- Increased workforce productivity and flexibility toallow for safe reallocation of resources in a more costeffective manner;
- Improved communication and coordination between departments with common goals and objectives;
- Short interval controls installed on all critical processes;
- Creation of a continuous improvement system and culture;
- Reduced spending on: overtime, raw materials, waste, energy and contractors.
