BRE Services was engaged to assist with an ongoing continuous improvement project, where areas for improvement were to be hypothesised, delivered to the business for resource approval, then executed and measured to quantify each areas success and business value.
Within this project, works completed include installation of new turbidity meters to increase accuracy of flushes and mitigation of product waste, detailed analysis of network performance to reduce data inaccuracies, end-of-batch sequence optimisation and enhancing the user interface to give advanced metrics and flexible control functions to the operators to assist their decision-making process.
The measurable output of these projects is a reduced amount of product making its way to drain, reduced load and chemical dosing on the trade waste system as a direct response to the reduced wastage, as well as enhancements to the product delivery and queuing sequences to the fill lines, meaning improved machinery uptime and a more constant output of product from the plant.
Savings identified through minimising product waste were proven to be 125kL per month, equating to $700K per year. Improvements to process and machinery uptime helped the production team justify additional batches per shift, and this increased throughput, coupled with the cost savings on equipment cleaning and trade waste, resulted in multi-million dollar savings for the business.
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