Case study · Oilseed processing
The plant could run harder, and schedule control was living in a spreadsheet.
An oilseed processing plant, crush and refinery.
Results at a glance
$13M
of savings through week 35 against a $3M plan, a $10M favorable variance.
+38% / +20%
Refinery throughput 25M to 34M lbs a week, crush 104M to 125M, on the same equipment.
33% / 23%
Better than base on outside labor against a 15% goal, and on outside repair and maintenance against a 12% goal.
The situation
Daily Schedule Control and Short Interval Control, the check on performance in short blocks through the shift rather than at the end of it, were kept in Excel.
What we did
The full tiered operating system went in: daily review meetings, Tier 1 and Tier 2, shift huddles and structured handoffs, gemba walks, an action register, a daily and weekly operating report, and Leader Standard Work, with schedule control moved into the plant’s own visualization system and a maintenance work management playbook behind it. The gains came from planning, scheduling and labor allocation discipline, with no reduction in work completed.
The result
Every figure, and how it was confirmed.
$13M
of savings through week 35 against a $3M plan, a $10M favorable variance.
+38% / +20%
Refinery throughput 25M to 34M lbs a week, crush 104M to 125M, on the same equipment.
33% / 23%
Better than base on outside labor against a 15% goal, and on outside repair and maintenance against a 12% goal.
As reported by the principal
How we report valueNext step
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