Maintenance & Reliability
Results
GP’s maintenance and reliability team focuses on rapid return, typically delivering a 5- to 33-fold return on consulting dollars invested. We approach every engagement as though your CFO were auditing the cost-benefit ratio. Therefore, your organization will quickly realize tangible results and build momentum through our focus on critical value streams and application of the elements of our robust approach.
Gain long-term results: A study of services for Gerdau Ameristeel
Using a rigorous selection process that began with 17 firms, Gerdau Ameristeel chose
GP as its partner for an initiative to install “world-class” leadership,
maintenance, and operating practices companywide; and developed internal capability
for continuous improvement.
- Conducted three-day Leadership Summit for the top leaders in the company—Topics:
Leading Change to Become World Class, Agreement on Companywide Values, Mission,
and Business System (first year).
- Conducted two-day Leadership Summit for the top leaders in the company—Topics:
Leadership Competency, Effective Decision Making, Unleashing the Power of Culture,
and Building Commitment (second year).
- Developed internal resources—applied a learn-do approach
to develop competency in the tools of World-Class (i.e., TPM, lean manufacturing,
Six Sigma, and management systems).
- Developed and deployed the Gerdau Ameristeel Business System—A
system that sets the standards for managing and operating the company by working
with company leaders to enhance the existing management systems, align leaders to
the improved systems, and document the systems in the Gerdau Ameristeel Business
System Handbook. The system includes:
- Management systems
- Annual action plan process
- Annual action plan progress reviews
- Standards for management and operations
- Training and coaching to those standards
- Standards audits
- Treatment of abnormalities
- Production system
- Focus on the front-line associate
- Root cause failure analysis
- 5S and Visual Controls for workplace organization
- Routine Equipment Care (Autonomous Maintenance)
- Planned Maintenance–Reliability Centered Maintenance, Planning, Scheduling, and
Preventive and Predictive Maintenance
- Spare parts management
- Quick changeover for equipment
Results (The following results are representative for each mill):
- Cost of mill changeover reduction of $1.3 million/year
- Furnace uptime improvement of $0.5 million/year
- Shift routine maintenance to operators improvement of $1.4 million/year
- Approaching industry benchmarks for key metrics: billets between cobbles improved
from 120 in 2002, to 668 in 2003, to greater than 3000 in Jun 2004
- Changeover time reduction on the roll line from average of 24 minutes, to less
than 6 minutes
- Melt Shop electrical delays reduction from 1132 minutes in October 2004, to 313
minutes over six months
- Mill’s score on a corporate-wide standard audit improvement from 2% to 83%, a
Gerdau North America benchmark
- Equipment modifications identification to support reduction to setup time
- Setup time standardization across all four shifts
- Increased employee engagement. As one supervisor stated, “I get more accomplished,
but it is easier (I used to work harder and get less done)”
- Role change for managers; Attitude and confidence have noticeably improved
Expect results that last. GP not only helps you achieve hard dollar savings, we
also have a lasting effect on your culture and your employees.
“I’ve seen
more change in a week than we’ve done in 20 years!” —A union member
from National Forge
A superintendent said, “I held everything close. My supervisors had to chase
me down to ask me to make decisions. Now they are making the decisions. I have to
tell you, life has gotten easier for me.” In response, his supervisor said, “Yes,
and I really like the change too. I used to wear out my boots looking for him!”
—Gerdau Ameristeel employees at a project review
Contact us today to learn more about GP’s maintenance reliability training results: