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 Results - Turnaround of Australasian metals manufacturer  

Context / scope of project : This site was unprofitable and under enormous community and government pressure due to excess emissions of potentially harmful metals. The operations had availability problems and the emissions were a symptom of unstable operations. PIP’s brief was to stabilize the operations, fix the emissions problem, reduce costs, build skills and sustainable systems and processes.

Client achieved:
$80m annualised improvement
Reduction of total number of injuries by 15%

Production increase: Zinc & Silver up 28%, Lead up 25%

Conversion cost/t down 10-15%

Total No. of injuries down by 15% from 2000

Emissions at historic lows

$13m saving in feedstock

Developed capability to produce higher grade product ($4mpa)

Average payback on initiatives < 4 weeks



   
   

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What we did:

Value Driver Trees – “Where’s the money?”
Debottlenecking
Variability reduction

Extension of Campaign Length – redesign planned shut solutions

Contractor Management

Cost Reduction – chemicals, logistics, waste reduction

Raw material optimization

Response plans, variance and non-conformance reporting
Accountabilities and reviews
Procurement


 
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