The Challenge
![opportunities-project-planning](/app/images/pt/projects/Accelerated_plant_shutdown_pro.png)
Problem
• Summer shutdown maintenance with many inefficiencies and a lack of standards
• High manpower costs (80 external resources)
• Long duration (3 weeks)
Root Causes
• Spares/tools not ordered in advance
• Critical Plan not visible
• Tasks planned with a lot of safety (buffer)
• Little time invested in task and resource planning
The solution
![mission-control-meeting-plant-shutdown](https://kaizen.com/app/images/pt/projects/Accelerated_plant_shutdown_mis.png)
• Pull Planning with Time and Cost Buffers
• Visual Management Boards for work and KPI monitoring
• Spare parts stored near machines, and tool/consumable kits prepared
• Daily cost control
The Results
The project resulted in Annual Savings of £2.5 million.
![manpower-cost-reduction-benefits](https://kaizen.com/app/images/pt/projects/Accelerated_plant_shutdown_ben.png)
Manpower cost reduction
Manpower costs reduced by 25%
![shutdown-duration-benefits](https://kaizen.com/app/images/pt/projects/Accelerated_plant_shutdown_ben%20-%20Copy%201.png)
Shutdown duration
Shutdown duration reduced by 10%
#process manufacturing #research and development #maintenance
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