Our client is a chemical company and the second-largest producer of PVC (Polyvinyl Chloride) in Europe. The group employs 1,400 people and generates a turnover of around 1.2 billion euros. Its activities are primarily located in France, reflecting a strong national presence in the industry.
Key Challenges
- To describe the current situation of two sites of the client in terms of maintenance and reliability
- To identify gaps and areas of improvement and define a roadmap to reduce the gaps
- To align with local people, middle and top management
Approach
1st step, Rapid Assessment on two sites. The objectives were:
- To assess value creation levers
- To identify key opportunities & high-level roadmap
- To Support go/no go decision for operations improvements
2nd step, Operations Analysis on two sites. The objectives were:
- To determine and quantify opportunities (business case)
- To align strategy with top and middle management
- To detail the roadmap by workstream
The next step would be to implement the defined roadmap on the two sites where the operations’ analysis was made.
Results
Maintenance:
- Estimated efficiency gain for site 1: 20-25% on FTEs → 1-2M€ (to be negotiated with sub-contractors)
- Estimated efficiency gain for site 2: 12-15% (internal) 15-17% (subcontractor) → 420-482K€
Reliability:
- Site 1: Estimated reduction of the technical production losses by 30-40% (product 1) and 40-55% (product 2)
- Site 2: Estimated reduction of the technical production losses by 35-47% (line 1) and 40-48% (line 2)
