Real-world examples of measurable project results
Metal processing
- 30% increase in line efficiency without
a single new hire - Considerable raw material waste reduction achieved (equivalent to cost of 300% of the workforce)
Metallurgy
- Building an improvement idea
and innovation system for operator level - Engaging 1360 people in improvement idea system (instead of 38 participants earlier)
- Significant increase in quantity
and quality of the improvement ideas
Open pit mine
- 10% production increase with no CAPEX
- Savings of 4.5 mln EUR due
to improvement projects - Zero serious safety incidents during the project (before: 2-3 lethal cases per year, many serious injuries)
Chemical
- Significant lowering of equipment stoppages, increasing availability
- Savings of 3.5 mln EUR due
to improvement projects linked
to improved processes an systems
Pharmaceuticals
- 15% of production efficiency increase, no new line CAPEX needed
- 21% reduction in raw material (API) waste
Cement
- Increasing performance by 14% with
no CAPEX investment - Building a transparent management and reporting system
- Lowering losses of auxiliary materials by 25%
Steel mill
- Reduction of defect rateto 1% (equivalentto 1 million EUR)
- Savings of 3 mln USD due
to reorganization of spare-parts management processes - Shortening maintenance stoppage time and maintenance errors/corrections by 34%
Steel mill
- Significant shortening the new plant start-up time, requiring 45% performance increase
- Savings of 8 mln EUR due
to re-organizing of (raw) materials management
Electro-energy
- 46% increase in performance due
to re-organizing the shop floor
and changing the motivation system - 23% decrease in delays of product delivery to customers
- 52% decrease in number of quality problems
Food processing
- Changeover and setup time reduction
- 50% increase in productivity due
to implementation of improvement projects
Food processing
- 28% increase in performance due
to work reorganization - Material waste reduction equivalent
to cost of 30% of the workforce
Food processing
- Increasing equipment availability
by 9% points - Lowering spare parts stock by 25%
- Improving maintenance work quality
& lowering machine failure rates