Operations Consultancy for Waste Reduction

Overview

This case study outlines a successful operations consultancy engagement for a waste reduction initiative in the paper industry, which significantly improved profitability by reducing waste and optimising operations. Over eight months, the project generated $4.3M in annualised savings through systematic problem-solving and collaborative execution.

Challenge

The primary challenge was excessive waste generation, leading to high overhead costs and reduced profitability. The root causes were a combination of equipment stability issues and a lack of organisational focus on waste reduction. Addressing these required both technical improvements and a cultural shift within the operational teams.

Solution

A structured approach was undertaken to tackle the waste problem effectively:

• Waste Loss Assessment: Conducting a thorough evaluation to quantify and identify key sources of waste.
• Problem-Solving & Root Cause Analysis: Engaging engineering and operational teams to diagnose stability issues and inefficiencies.
• Action Plan Development: Creating a targeted waste reduction strategy that aligned with operational workflows and priorities.
• Operational Collaboration: Working closely with the teams to implement process improvements and ensure long-term waste reduction efforts were sustainable.

Results

The initiative delivered substantial financial and operational benefits:

• Achieved $4.3M in annualised savings within eight months.
• Improved equipment stability, reducing process variability and waste generation.
• Fostered a stronger organisational focus on waste reduction, embedding it into daily operations.

Lessons Learned

Key insights gained from this project included:

• Implementation Matters as Much as Problem-Solving: Partnering with clients to execute solutions was crucial for lasting success.
• Visibility Drives Resolution: Making waste levels visible enabled teams to identify and address inefficiencies proactively.
• Cultural Change is Key: Encouraging a mindset shift towards waste reduction helped sustain improvements beyond the project timeline.

Conclusion

This waste reduction project demonstrated how a structured, collaborative approach can lead to significant cost savings and operational efficiency improvements. By addressing both technical and cultural challenges, the initiative set a precedent for ongoing waste management and process optimisation in the paper industry.

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