Enhancing operational efficiency of maintenance operations and embedding best practices across 15+ sites

The mission

Improving the operational efficiency of maintenance activities for an entity of more than 15 industrial sites and over 20k people, while ensuring a profound cultural shift and fostering a performance-oriented mindset.

The challenges

• Measure and quantify operational efficiency without finger-pointing
• Ensure consistency between the roadmaps of ongoing projects within the entity
• Improve working conditions, safety and security
• Meet political expectations
• Enable a sustainable performance operational mindset

The approach

Initial farming phase with :

• A pilot site to test the approach: Irritant mapping, Impact study, Prioritization of issues to be addressed, Definition of more than 100 improvement opportunities (customized for each site)
• Surveys to bring other sites on board (4000+ responses analysed)

Implementation phase with 3 different timetables to ensure in-depth transformation :

• Short-term: deployment of a limited number of “quick wins” on all sites each quarter
• Medium-term: support each site to take ownership of its efficiency challenges and build a performance culture
• Long-term: in-depth challenge of a shortlist of projects impacting all maintenance teams

The impacts

• 10% improvement in operational efficiency (in number of maintenance activities done per day)
• Saving of several hundreds of production hours
• National productivity tool built and deployed across all sites to track and enhance operational efficiency