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