Process Mapping

CASE STUDY:
How Dominion Salt achieved 20% productivity Gains and annual savings of 200k!

… Increasing demand and the need to improve delivery In-full score to the final customer prompted a focus on production out-put.

As part of the Improvement Directs Worxsmart Lean Program, we had been introduced to Process Mapping and Project Excellence training and skills so we initiated a  cross-functional group to target improved performance from the Salt Refinery Plant :

Through the process mapping we identified 45 significant opportunities for improvement and then used our Project Excellence tools to help us target, and prioritize…
 
One of the targeted opportunities was to reduce the amount of water added during the production process…often for flushing and rinsing and removing salt build up…which are essentially non-value activities! and given the salt plant is design to wash, refine and dry salt, adding water in some instances is counter productive. This became the Water Reduction Project:

We were able to use the Worxsmart practicle step by step tools to work the group through the initial project steps :
  1. Involve the right people: This included fully engaging the production team and front line leaders
  2. Gather data: We listed and recorded all water use , reasons or causes and ideas and solutions
  3. Group and set priority: We ranked the opportunities using a decision matrix format
  4. Take action: Then we sequenced the action steps onto a time –line of urgency
Task BoardAction Plan

Project results and benefits

People:
  • Improved knowledge of plant design and capability
  • improved standard work routines
  • Reduced frustration: reduction in repetitive cleaning
  • Increased engagement
Quality:
  • Reduced 2nd grade salt from wash / spillage
  • Reduced rework
Delivery:
  • 20% Productivity gain as a results of reduced downtime for cleaning / flushing
  • 15% Reduced water usage $ / year
Cost:
  • Energy savings: 10% / ton improved 
THIS IS JUST ONE EXAMPLE OF PROJECT IMPROVEMENT AT DOMINION SALT…THE WORXSMART PROGRAM CONTINUES TO DELIVER ANNUAL SAVINGS / GAINS OF 200K + PER YEAR