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When global refractory leaders RHI
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and Magnesita merged in 2017, the number
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of plants in its production
network increased significantly
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leading to key challenges
that needed to be addressed.
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When the two companies merged, we got
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to a much larger network, also
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with subsequent acquisitions,
than we had initially.
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And these plants were never
truly aligned in operational
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practices, especially maturity in health
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and safety practices.
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Other challenges included
a significant mismatch in
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comparison data between sites,
differences, and processes,
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and quality and waste across the network.
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There was also an imperative
to cut cost from the system.
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The perceived solution was
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to build up a global production system.
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so-called the Operations
Excellence System,
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and for those, we chose BCG as a partner
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to support us in structuring
it, in developing it,
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and very important, to share
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outside-in best practices
from other industries.
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First and foremost, inside
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of our operations excellence system,
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standardization has the highest
priority, always beginning
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with health and safety.
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Second, to do the right decisions
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and to compare fair with the
OES, we increase transparency.
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We will implement a digital
solution which will give us a
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standard set to have
the same information all
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around the globe embedded in the same way.
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The third one, which is
very, very important for us,
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to set up the base for a
continuous improvement way of life,
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to really have improvement
in our mindset every day,
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every hour, every minute,
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and to do it in a standardized, agreed,
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and aligned way all
around the RHI Magnesita globe.
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Following early feedback
from the shop floor deployment
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of OES took place across the regions in a
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step-by-step approach.
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It has a set of guidelines
which will help us in improving
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workplace safety,
improving the efficiency,
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improving the quality of
product, improving the lead time
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to our customers, and will
help us in improving our
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product delivery.
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It created improvements
across the plants
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and people actively discussed health
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and safety topics, efficiencies,
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and also process improvements.
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The OES provide great improvements
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in our plants, specifically
related to the environment
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and there is opportunity to
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increase specific KPIs
in our plant as well.
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Now we clean it, separate, test,
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and send back to the raw material intake,
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which leads to a saving by 300
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to 400,000 euros per year.
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Most, probably more.
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Overall, OES achieves a
step-change in cost savings,
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in a conversion cost of about
10%, which translates to 80
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to a hundred million euro per annum.
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These are wonderful three words,
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Operational Excellence
System, a set of systems, set
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of guidelines, set of SOPs
to standardize operations
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to improve the overall
efficiency of operations.
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So that's what OES stands for.