RLG engaged in a 12-month project with this industrial fertilizer plant to undertake a program of performance improvement and continuous improvement initiatives, centered on reliability, through strong leadership. Emphasizing uptime as the greatest opportunity to enhance bottom line results, the RLG team focused on:
- Developing an internal team to assess plant health and take bold actions to mitigate threats
- Aligning metrics focused on uptime and developing tiered accountability across the site to drive front line decisions
- Strengthening their Operating Rhythm™ to lever results, successes, opportunities and required actions on backlogs, preventive maintenance compliance and workflow
- Building leadership behaviours and skills through one-on-one coaching and workshops
Project Highlights
- Within the year, seven production records were broken
- Because of a team-based, thorough review, maintenance backlog was culled by 10,000 hours
- Both Ammonia and Urea plant uptime rose dramatically, as shown in the chart, partly due to a renewed focus on reliability bad-actors and optimized planned and un-planned shutdown events
- Leadership at all levels were developed through instruction, feedback and coaching, with progress tracked
- A powerful weekly boardwalk broke down organizational barriers to create one-team across Operations, Maintenance, Shipping, Engineering, Safety and Reliability groups
“RLG accelerated our ability to put ideas into action.”
OPERATIONS SUPERINTENDENT
“The TMP™ process was the first step in our seamless execution of the … project.”
FRONT LINE OUTAGE COORDINATOR
“You were here to help us, not to tell us what to do.”
RELIABILITY SUPERVISOR