Continuous Improvement System Implementation
Generation of additional financial returns through the effective collection, analysis and implementation of improvement ideas by the workforce.
“My experience working with RLG International has long convinced me: if they decide to take on a project, the project will surely succeed. CIS Implementation is yet another example of that. Together with RLG we first came up with this system, worked on its development, and today it is of interest to both downstream and upstream.”
— Head of Production Planning Division
Context/Challenge
Leadership of the large European refinery asked RLG International to aid in the development and implementation of a continuous improvement system and culture that would generate additional financial returns through:
- the effective collection, analysis and implementation of improvement ideas by the workforce,
- improvement of quality indicators closer to world-class, and
- involve the workforce in the process of production efficiency improvement.
Approach
At the first stage, a series of idea generation and TMP™ (Theoretical Maximum Performance) sessions were conducted, and workgroups in three key areas were created, to:
- increase rates of crude conversion,
- improve energy efficiency, and
- reduce fuel utilization and losses.
At the second stage, to ensure continuing progress and sustainability, the Refinery organizational structure was adjusted to create a Continuous Improvement System support team, under the Commercial Department. RLG helped design and implement this change, building confidence and capability among the new and adjusted roles.
At the third stage, focus was on individual and team coaching of leadership and professional competencies for key participants in the continuous improvement process. At this stage, an effort was made to enable knowledge transfer of RLG tools and processes, for the collection and implementation of ideas.
Result
- Financial impact is recorded at $265 M,
- 88 idea authors, 232 ideas registered, 53 ideas implemented,
CI System implementation project resulted in:
- Management support,
- Fully trained dedicated team,
- Embedded Operating Rhythm™,
- Procedures and guidebook,
- Motivation system rewarding involvement and results, and
- Clear growth plan and vision.
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