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Atofina – Antwerp, Belgium

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Background:

  • ATOFINA – Antwerpen, Belgium – Dutch is primary language at facility
  • Polyethylene; 340,000 metric tons of pellets and fluff per year, 4 dozen formulations and colors, 5 reactors (#6 in construction), 250 employees, independent management, Average annual reliability loss of 16,200 tons (23,500 in previous year)
  • Elastomers; 95,000 metric tons of pellets per year, 2 dozen formulations , 4 finishing lines, 190 employees, independent management, Average annual reliability loss of 6,500 tons (16,400 in previous year)
  • Central Maintenance Group; 70 employees, SAP R/2 CMMS, Outage preparation timelines of 6 months or less
  • Company undergoing a 10% reduction in management staff corporate-wide.

Process Results:

  • Implemented revised Work Management Process procedures
  • Trained and coached to KPIs, Leadership model, Standardized roles and responsibilities (plant manager through head operator)
  • Facilitated development of plant strategies (mission, vision, goals and 5-year strategy)
  • Re-scored Reliability Grid after implementation - 23% improvement

Bottom-Line Impacts:

  • PE - 32% reduction from 4 year average reliability losses
  • PE - 53% reduction from the 2000 losses
  • EL - 48% reduction from the 2000 losses
  • Overall site - 14% reduction from the 4 year average reliability losses

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