WEBVTT 1 00:00:01.020 --> 00:00:03.390 When global refractory leaders RHI 2 00:00:03.390 --> 00:00:07.380 and Magnesita merged in 2017, the number 3 00:00:07.380 --> 00:00:11.100 of plants in its production network increased significantly 4 00:00:11.100 --> 00:00:13.770 leading to key challenges that needed to be addressed. 5 00:00:15.030 --> 00:00:17.430 When the two companies merged, we got 6 00:00:17.430 --> 00:00:19.950 to a much larger network, also 7 00:00:19.950 --> 00:00:24.240 with subsequent acquisitions, than we had initially. 8 00:00:24.240 --> 00:00:28.410 And these plants were never truly aligned in operational 9 00:00:28.410 --> 00:00:32.370 practices, especially maturity in health 10 00:00:32.370 --> 00:00:34.140 and safety practices. 11 00:00:34.140 --> 00:00:36.960 Other challenges included a significant mismatch in 12 00:00:36.960 --> 00:00:40.920 comparison data between sites, differences, and processes, 13 00:00:40.920 --> 00:00:43.350 and quality and waste across the network. 14 00:00:43.350 --> 00:00:46.920 There was also an imperative to cut cost from the system. 15 00:00:46.920 --> 00:00:48.420 The perceived solution was 16 00:00:48.420 --> 00:00:51.660 to build up a global production system. 17 00:00:51.660 --> 00:00:54.510 so-called the Operations Excellence System, 18 00:00:54.510 --> 00:00:57.330 and for those, we chose BCG as a partner 19 00:00:57.330 --> 00:01:00.600 to support us in structuring it, in developing it, 20 00:01:00.600 --> 00:01:03.000 and very important, to share 21 00:01:03.000 --> 00:01:06.240 outside-in best practices from other industries. 22 00:01:06.240 --> 00:01:08.640 First and foremost, inside 23 00:01:08.640 --> 00:01:10.680 of our operations excellence system, 24 00:01:10.680 --> 00:01:14.490 standardization has the highest priority, always beginning 25 00:01:14.490 --> 00:01:15.870 with health and safety. 26 00:01:15.870 --> 00:01:18.690 Second, to do the right decisions 27 00:01:18.690 --> 00:01:23.640 and to compare fair with the OES, we increase transparency. 28 00:01:23.640 --> 00:01:28.560 We will implement a digital solution which will give us a 29 00:01:28.560 --> 00:01:32.760 standard set to have the same information all 30 00:01:32.760 --> 00:01:35.760 around the globe embedded in the same way. 31 00:01:35.760 --> 00:01:38.460 The third one, which is very, very important for us, 32 00:01:38.460 --> 00:01:43.380 to set up the base for a continuous improvement way of life, 33 00:01:44.413 --> 00:01:47.947 to really have improvement in our mindset every day, 34 00:01:47.947 --> 00:01:48.780 every hour, every minute, 35 00:01:48.780 --> 00:01:51.630 and to do it in a standardized, agreed, 36 00:01:51.630 --> 00:01:56.340 and aligned way all around the RHI Magnesita globe. 37 00:01:56.340 --> 00:01:59.400 Following early feedback from the shop floor deployment 38 00:01:59.400 --> 00:02:01.800 of OES took place across the regions in a 39 00:02:01.800 --> 00:02:03.660 step-by-step approach. 40 00:02:03.660 --> 00:02:07.800 It has a set of guidelines which will help us in improving 41 00:02:07.800 --> 00:02:11.430 workplace safety, improving the efficiency, 42 00:02:11.430 --> 00:02:14.040 improving the quality of product, improving the lead time 43 00:02:14.040 --> 00:02:18.060 to our customers, and will help us in improving our 44 00:02:18.060 --> 00:02:19.950 product delivery. 45 00:02:19.950 --> 00:02:24.300 It created improvements across the plants 46 00:02:24.300 --> 00:02:27.120 and people actively discussed health 47 00:02:27.120 --> 00:02:29.550 and safety topics, efficiencies, 48 00:02:29.550 --> 00:02:32.220 and also process improvements. 49 00:02:32.220 --> 00:02:36.270 The OES provide great improvements 50 00:02:36.270 --> 00:02:40.170 in our plants, specifically related to the environment 51 00:02:40.170 --> 00:02:42.990 and there is opportunity to 52 00:02:42.990 --> 00:02:46.860 increase specific KPIs in our plant as well. 53 00:02:46.860 --> 00:02:51.150 Now we clean it, separate, test, 54 00:02:51.150 --> 00:02:55.710 and send back to the raw material intake, 55 00:02:55.710 --> 00:02:59.710 which leads to a saving by 300 56 00:02:59.710 --> 00:03:01.840 to 400,000 euros per year. 57 00:03:01.840 --> 00:03:03.670 Most, probably more. 58 00:03:03.670 --> 00:03:07.690 Overall, OES achieves a step-change in cost savings, 59 00:03:07.690 --> 00:03:11.860 in a conversion cost of about 10%, which translates to 80 60 00:03:11.860 --> 00:03:14.200 to a hundred million euro per annum. 61 00:03:14.200 --> 00:03:15.970 These are wonderful three words, 62 00:03:15.970 --> 00:03:19.960 Operational Excellence System, a set of systems, set 63 00:03:19.960 --> 00:03:23.440 of guidelines, set of SOPs to standardize operations 64 00:03:23.440 --> 00:03:26.440 to improve the overall efficiency of operations. 65 00:03:26.440 --> 00:03:28.960 So that's what OES stands for.