Client: Ineos Chlor Ltd
Sector: Process Industries, Manufacturing & Packaging
Key tools or services
Implementation - Problem Solving, 5S
The consultant was able to challenge established practices using experience gained working with other companies. By applying the Masterclass process, it was possible to engage people in a structured approach to problem solving.
Jon Whieldon, CM2 Operations Manager
Requirement
Ineos Chlor's Runcorn site has been pursuing continuous improvement and operational excellence for a long time now, however, there was a feeling that operators had become rather less involved in recent times and a fresh approach was needed. The CM2 chloromethanes plant, which converts 500Te a day of chlorine into derivatives such as solvents, decided to engage us.
Response
Although Ineos has had huge successes within its manufacturing improvement journey over the last few years, it was recognised that they still needed a greater level of involvement in improvement processes from the operating teams.
We offered a straight forward approach that we felt could deliver this step change, as well as offering us the opportunity to learn and apply best practice from elsewhere in the industry. We also supported the transfer of skills so that we could then continue the improvement journey using the Masterclass Process ourselves, long after they had left us, thereby truly providing a long term solution
Irene Robertson, Manufacturing Improvement Manager
CM2 chose to focus on their effluent and organic recovery plant operation as it was an area that demanded a lot of operator attention, but, being out of the way, was hard to keep up to the highest standards. They were working hard but could they work smarter?
Result
- £100,000 saving on recovered product
- 87% reduction in number of operator interventions
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