Case study: Performance improvement through the integration of modernised with existing operating plants in India

Management recognised the need to bring together the existing and new operating units in a way that would optimise output and quality and reduce operating costs. The key performance indicators that would need to be achieved for the existing operating units to match the requirements of the new operating units had already been identified.

A Diagnostic Study conducted by Corus Consulting identified:

• Potential bottlenecks to production;
• The key operating parameters that would need to be achieved in order to meet the key performance indicators;
• The existing structure and reporting relationships within the business and the competing elements that would hinder the process of change;
• The current technology, plant condition and capability;
• The systems, procedures and practices in use;
• The existing level of skills and competencies.

Corus Consulting adopted an approach that set out to:

• Create the conditions that enable people to work effectively and prepare people to work.
• Assess the organisation, systems and procedures within which the people work and make changes where it is found that these are inhibiting achievement of business objectives.

This involved:

• The selection and subsequent phased training within Corus of the project teams that would lead the process of change;
• The provision of technical assistance to those projects teams throughout the duration of the project;
• The provision of practical training on site to improve craft skills necessary for the maintenance of specific items of equipment;
• The reorganisation of functional departments in order to improve the level and quality of support to the operating units;
• The setting up of a procedure for joint (Client and Corus Consulting) monitoring and reporting of progress.

These activities took place of a period of some 3 years at the end of which some 75% of the key performance indicators had been achieved. Since that time a further 20% have been achieved and the remaining 5% are steadily improving.