Improving Operational Efficiency for a Leading Fertilizer Company with Multi Locations Plants
Problem Statement
The Operational efficiency affected by
- Less focussed Material Management,
- Too many machine breakdowns reflecting lack of Preventive Maintenance planning,
- Constraints observed in layout of plants leading to space availability issue, forcing sequential activities leading to efficiency loss
- Need to revisit the process to optimize usage of equipment to improve process time
Our Solutions
- Material Management:
- Unloading efficiency and optimization of the type of delivery vehicles
- Making proper arrangement for material storage at port reducing Quality issues
- Machine Breakdowns:
- Critical/Bottleneck equipment Preventive Maintenance Schedule creation
- Listing out the critical spares via VED ( Vital Essential & Desirable ) analysis
- Layout optimization:
- Packing area segregation based on output points
- Inbound/Outbound area segregation
- Process mapping
- Based on product category define the Process
- Redesign the equipment sequence to allow product based process flow.
Impact
- Inbound delivery downloading – Improvement opportunity by 28%
- The breakdown can consistently reduce by 40%.
- Continuous monitoring of spares, expected to reduce the down time by 30%
- Parallel outbound of two grades successful for two weeks , increasing service level.
We love to hear from you
Please call or email contact form and we will be happy to assist you.
We love to hear from you
Please call or email contact form and we will be happy to assist you.
