SABIC UK Petrochemicals Ltd expects annual productivity gains of over £10 million following an improvement programme, led by Reliable Manufacturing, at its ethylene liquefaction plant on Teesside.
The programme has delivered a "dramatic turnaround" after nearly 20 years of under-investment by the previous owners at the 700-employee site, according to Reliable Manufacturing – a change-management company, based in Warrington, UK.
After just 18 months, the Teessite site has noted a major reduction in plant breakdowns and performance issues. Further savings of over £1 million a year were delivered through better communications between Teesside and SABIC's other main UK site at Wilton, near Redcar.
'Asset care improvement' teams have uncovered issues making great efficiency savings, which on just one propylene dryer is estimated to be in excess of £400,000 a year, a statement from Reliable Manufacturing explained.
“We’ve managed to achieve reliable production week after week, despite the plants age and without any significant investment,” said Wayne Alexander, former senior operations manager. “It’s about the teams operating the plant correctly, being slick at what they do, and working to plans and targets.”
“Our best results are in what have traditionally been our worst months, so the performance is stellar, especially if we can lock it in going forward; that’s the next phase of the project," added Alan Wasson, engineering director.
Chiller rejuvenation work
An important aspect of the project was winning the support of the "previously disenfranchised workforce," Reliable Manufacturing's statement continued.
This, it said, involved adopting an approach to "defrost the existing culture" and establish a new one of ongoing continuous improvement. Employees, thereby, got behind the project, with an estimated 75% of process team members involved in some way.
“It’s about having a workforce that’s really engaged and aligned with where the business needs to go and seeing their job as one of continuously improving business peformance,” said Mike Ducker, manufacturing director.
SABIC UK Petrochemicals is part of the European operations of Saudi-owned SABIC – one of the world’s largest manufacturers of chemicals, fertilisers, plastics and metals.