By putting in place key wiring strategies and employing robust coaching we help reduce downtime, optimise performance and increase production. We:
By implementing these key wiring strategies with our clients, we bring alive the success of this approach. For example, PIP helped one client cut shutdown frequency in half. Planned downtime fell from 5.5% to less than 3%. Some of the key areas of maintenance we have assisted our clients in delivering significant improvements include:
We help stabilise operations by systematically eliminating the repeat offenders.
Planned shutdowns represent both a high direct cost, and a large opportunity cost due to the associated lost production. Simply put, we help our client’s reduce these costs.
Done well, predictive and preventative maintenance allows you to optimise the economics of your equipment, saving significant time and cost, while keeping production on-line.
PIP worked for me at both UK Paper and Pasminco (Nyrstar) Risdon smelter. At these sites the [PIP team] helped my team deliver 25% and 12% volume improvement respectively, and 11% and 9% absolute cost reductions (20% cost/T). A large part of this was their work on maintenance, both planned and unplanned, dramatically improving the effectiveness and efficiency of our planned shuts and systematically eliminating causes for downtime. At one site unplanned downtime was reduced by 79%, while planned downtime was held constant. At another, total downtime was reduced by 60%. They reduced the costs of maintaining the equipment, reduced wastes and renegotiated key maintenance spends. Furthermore, this work led to significant improvements in the skills and morale of our workforce; improving retention at all levels. With PIP's help we delivered a significant improvement in bottom-line results, and also a culture of accountability and continuous improvement. The increase in tonnes (availability and broke) and reduction in costs was higher than expected, and the urgency and pace they brought, ushered in a whole new level of performance culture. [PIP's] consultants were exceptional, not only did they focus on implementation, and delivered results, but they did a great job of coaching all levels of our organisation.IAN HALLIDAY