Use Case 5- Secondary Steel Plant Productivity Improvement

Context

A large Steel group in India wanted to improve their plant and manpower productivity in 3 of their plants. In addition they wanted to benchmark operating parameters with global peers.

Our Work

For  operations and manpower study ,Experts  carried out the following activities

1.          Visited plants, interactacted with client and consulting team on ground

2.          Undertook plant walkthrough

3.          Reviewed data collected and analysis of the same

4.          Assessed the gaps in existing manpower deployment by working closely  with client  

6.          Problem solving discussions with team

7.          Presented to client team and assisted in buy-in discussions

8.          Provided inputs in the desired format as specified by the consulting team

 For Benchmarking study,  Mavensworld carried  out research on parameters outlined above by

·      Accessing databases , reports , news and publications related to the Coated Steel Industry

·      Consultation with in-house team

·      Analysis , triangulation and synthesis of findings

·      Report preparation and submission

Results

Over 75 improvement  ideas spread across pickling , galvanising , colour coating, cold rolling , electrolytic tinning, temper mills was presented which captured over 10% reduction in direct manpower and 12% improvement in overall productivity of the plants.

Benchmarking of over 300 parameters across 8 plants was presented which was used to improve line speeds , reduce downtimes and staff optimal manpower