We help our clients to enhance productivity and/or reduce costs while maintaining or improving their safety and environmental performance. Our consultants also work with capital project teams to optimise value and ensure effective construction and commissioning of new projects and major expansions.PIP’s approach systematically diagnoses operating performance, then prioritises the most significant drivers, leading to rapid and sustainable improvement. We have experience in coaching our clients and an extensive database of approaches and improvement ideas for all types of smelters and refineries.
Our consultants help identify and fix the weak points in maintenance workflow (initiation to execution) – both for shuts and operating periods - eliminating cost and reducing interruption to operations.We have proven expertise in focussing team resources on the priority Key Performance Indicators (KPIs) driving operational performance and relentlessly finding and removing obstacles to improvement.
Some feeds create huge work-in-process inventories – others can have your operation running like a dream. Some bring useful by-products, others build-up costly long-term liabilities and all result in different tonnages and revenues.Optimising the feed to your process may require data gathering and analysis that has not been done in your operation before. Ensuring this is done correctly requires the discipline to rigorously manage complex technical and commercial trade-offs to ensure your plant is running both smoothly as well as profitably. This effectively captures a lever of cash flow which may not be highly visible to your people. While this requires some effort, it has yielded tens of millions of dollars of annual value for our clients in a relatively short timeframe.
We help your teams identify and implement effective contractor management strategies tailored to your situation. Our expertise in procurement drives rapid savings through vendor consolidation, negotiation, usage reduction and controls, contract management, improved planning and approval processes.
Our processes assist your team to remove cost from capital projects at the design stage and to optimise sustaining capital expenditures. And we improve construction productivity to keep projects on track or bring them back on track if they fall behind.
I worked with PIP at Pasminco's (Nyrstar) lead/zinc smelter where volume was increased by 34%, emissions reduced by 50%, and cost/T reduced by 28%. At the time, I was Maintenance Manager, and together our teams delivered a 58% reduction in downtime on the bottleneck in seven months, along with a 12% reduction in site-wide maintenance spend. Volumes out of the site increased by 25%, emissions reduced by 50% and overall costs came down by 28%. Not only did the work achieve great financial results in a sustainable manner, but it transferred extensive skills to the client through PIP's approach of working closely with people, role-modelling behaviours and providing extensive coaching on the job. The PIP team was focused on what makes a difference, transferring an understanding of the key drivers of the business to our people. They combined intellectual rigour with coaching and wiring in strong but simple tools to build accountability and ownership.ANDREW BREWER