![P1020579 P1020579](https://businessactionlearningtas.com.au/wp-content/uploads/2016/07/P1020579-scaled-570x480.jpg)
Pot shell refurbishment
Project Objectives
- Analyse the current process for pot shell refurbishment and transport to and from Kempe engineering
- Recommend and justify improvements, that will reduce the cost of the process by 15% per annum
Project Team
![nick](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Nick.jpg)
Nick Williams
Kempe Engineering
![brian](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Brian.jpg)
Brian Lockhart
Bell Bay Aluminium
![ian](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Ian.jpg)
Ian Hutchison
Bell Bay Aluminium
![leigh](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Leigh.jpg)
Leigh Edgerton
CPT Engineering
Facilitators
![bob-cother-colour](https://businessactionlearningtas.com.au/wp-content/uploads/2016/08/bob-cother-colour.jpg)
Bob Cother
The Action Learning Institute
![bill-woodworth-colour](https://businessactionlearningtas.com.au/wp-content/uploads/2016/07/bill-woodworth-colour.jpg)
Bill Woodworth
Bell Bay Aluminium
Key measurables
-
Overall cost reduction of 15% per annum
- Target average labour hours per shell
Companies involved
-
Kempe Engineering (co-host)
-
Bell Bay Aluminium (co-host)
-
CPT Engineering
Approach taken
- Site tours and observation of processes at Kempe and BBA
- Value Stream Mapping of current processes
- Brainstorming sessions to generate improvement ideas
- Interviews with relevant stakeholders at both sites
- Root cause analysis and Cause/Effect analysis
- Development of improvement options, including:
- Improvements to the delining process at Bell Bay, which was causing significant damage and affecting work flow at Kempe Engineering
- Manufacturing cell design at Kempe including customised equipment
- Presentation of recommendations to senior management, including cost/benefit analysis
- Preparation of implementation plan
Summary of outcomes
- Cost and labour hour targets met through improved workflow at Kempe
- Significant additional savings through recycling of the ‘tails’ that conduct electricity into the pot shell
- Business retained by Kempe that had been lost or could be lost to offshore suppliers