Productivity Improvements – Case StudyCoal Terminal - NSW, Australia

Productivity Improvements

The Challenge

A local bulk material handling facility with multiple internal and external stakeholders was experiencing significant delays unloading trains.

Additional to the unloading issues was the on-time running performance of the network being 5.3% The entrenched problems negatively impacted the facilities inbound unloading plan and timetable.

The key challenges were to reduce the baseline unloading performance by 35%, process trains with no impact on road deliveries, and meet the rail network provider’s allocated rail departure timetable slot.

The Solution

EnterpriseIS conducted a detailed analysis of the challenge and tailored a site-specific education program to address the key issues and complexity of multiple internal and external stakeholders. An assigned cross-functional project team of transport and terminal employees analysed, implemented and delivered the project outcomes.

This team was coached and mentored by an EnterpriseIS Lean Six Sigma Black belt utilising several techniques from the Competitive Systems and Practices skill sets. Process tools such as SIPOC, time series maps and data collection plans were tailored to identify and remove multiple hidden process steps. They were identifying and eliminating these steps resulting in a reduction of 45% in unloading time.

The Results

• 108x the investment returned to the business

• Project payback period 3.5 days

• Mean train unloading time from 107 min to 62 min

• Four employees trained to Certificate IV in Competitive Systems & Practices

• Sustainable operations.

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