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Driving ResultsAll thoughts must be distilled into action and action that brings results.Feeding A Demand For MexicanSafety First. Safety Last.BUSINESS CHALLENGE The client is a major North American food company.Demand for its Mexican frozen food was booming, so it needed to maximizeplant production to guarantee customer satisfaction. The facility presenteda number of challenges, including an inexperienced group of operators andmechanics, a lack of structured processes and a divided managementteam with poor management practices. Equipment was showing signsof deterioration because of poor reliability and maintenance and therewas limited visibility into where and why bottlenecks were forming andthe best way to correct them. To further complicate things, the existingtortilla bakery section was to be decoupled from the rest of the productionline and a new one built in an adjacent building. Product quality and foodsafety were an absolute priority, so Celerant Consulting was appointed tohelp the company transform the site.CELERANT SOLUTION To ‘regain control’ of the production process theCelerant Team installed a cross-functional problem solving system tofix the root causes of recurring issues and used Closework ® to teachimproved methods on the line, facilitate clear communication and createa cohesive working environment. They also trained people for the separatebaking facility and integrated them into the new processes. Then whena sister production site was fire damaged and its production transferredover, Celerant supported the conversion of one line to include eggrolls,an entirely different process from anything existed. At senior managementlevel, Celerant also coached selected managers to promote fact baseddecision making and a real results focus.RESULTS The plant made a profit made for the first time in 3 years.•Overall OEE improved significantly and labor costs and materialwaste were reduced. •Emergency maintenance was halved andschedule compliance dramatically increased. •Preventive maintenanceprocedures, reliability SOPs and a new MCRS ® Management System todrive Continuous Improvement were installed.ManufacturingBUSINESS CHALLENGE The client, a leading North American chemicalscompany, first appointed Celerant Consulting for a major project at oneof its biggest plants that focused on waste water excursions, overallequipment effectiveness and operating budget improvement. Withsuccess in all areas, including a reduction in waste water excursionsto zero, Senior Management now wanted to use the momentum fromthat project to improve personal safety at the facility.CELERANT SOLUTION Celerant conducted a safety assessment and asa result partnered with the site leadership team to execute a safetyimprovement project to raise safety awareness and develop a culture andapproach that would drive sustainable safety performance improvement.To execute the project, the joint Taskforce focused its efforts on: SafetyStrategy including integration of site goals to corporate initiatives; SafetyInitiative Management with a focus on effectively managing executionof selected improvement initiatives; The Management Control andReporting System incorporating leading safety performance indicatorsin site safety performance review; Plant Safety Communications to raiseawareness on the job as well as awareness of new safety initiatives;Environmental Health & Safety Employee Councils to increase workforceengagement in safety improvement; Incident Investigation ProcessImprovement that included the consistent utilization of structuredproblem solving to identify and address root cause. The execution teamwas supported by an overall steering team that helped expedite decisionmaking and issue resolution.RESULTS The entire organization was successfully engaged throughoutthe project. •All project deliverables were completed. •The new systems,processes and behaviors that were implemented for a sustainablesafety culture meant that the organization could drive continuous safetyimprovement once the project was complete.‘I actually feel that we’re making a big contribution to the long termsuccess of the plant. I’ve never before worked on a project where I feltI was having that kind of impact.’ Client Co-Project LeadChemicals36 CLOSEWORK® GLOBAL REVIEW 2012