Lucite International’s (LI) Cassel site in Billingham, UK has won the Chemical Industry Association’s BIS Excellence in Engineering Award 2012. The award was made in recognition of the significant contribution that engineering improvements have made to site operations and overall business performance. These improvements have been achieved by the local team, which has focused on delivering better overall equipment effectiveness (OEE) using the Company’s rigorous ‘Manufacturing Excellence’ programme, which helps to drive and sustain world-class practices.
An initial analysis of the site’s OEE identified sizeable value gaps in the engineering availability of the assets, which provided the basis for an ‘Asset Care’ programme of work to develop and then implement improvements for each operational area. Delivery of the entire improvement programme has resulted in the engineering availability of the critical plants rising to the world-class target of 98% from an average 91% in 2007. The improved engineering availability has also contributed at least 50% of Cassel site’s 10% OEE improvement over the past five years. And, as a result of higher equipment availability and more focused maintenance activities, costs have been controlled through the period at a consistent 3% of Asset Replacement Value.
New team skills and knowledge were required and as a result two engineers have been supported through an MEng in Asset Management with a third in the final year of the course. Their contribution to the success of the project has been invaluable and has enabled the wider engineering team to drive further improvements.
These improvements have enabled better sales and operations planning, stock reduction and an ‘On Time in Full’ (OTIF) performance consistently above 99%, which in turn have allowed the commercial teams to develop long-term contracts with customers for the supply of LI’s products. Reliability and consistency of high quality supply means that customers value LI as a professional and stable partner, which has led to the Company growing its market share by 50%.
Site Director, Melanie Jury said: ‘Winning this award is wonderful recognition of the site team’s consistent hard work over many years of operation. The continuous improvement culture is well established at Cassel and hitting our targets only leads us to review and set new ones. We are focused on remaining the very best Methyl Methacrylate producer, which will help us to secure a sustainable future.
Young Ambassador 2012 Awards
Two Lucite International (LI) employees were short-listed for the CIA Young Ambassador 2012 Award, which recognises an individual who demonstrates communications skills and leadership that contribute to the on-going growth and success of the chemical industry.
Jonathan Moore, Process Engineer at LI’s Cassel site with 3.5 years service, was praised for his role as a Science Technology, Engineering and Mathematics (STEM) ambassador and involvement with the Teesside IChemE committee. Jonathan has also been involved in site school visits to inspire 11-16 year olds to choose a career in the chemical industry.
Tina Edwards, Senior Buyer, was recognised for actively promoting the chemical industry to different disciplines both inside and outside the Company. As well as being an enthusiastic member of the Purchasing team, Tina is a passionate contributor to the site SHE Committee, where she has helped deliver improvements such as, replacement of IBCs for transport and storage and implementing antistatic work wear across the site.
Short-listed for Manufacturing and Resource Efficiency Award
Lucite International’s site at Darwen was short-listed for the ABB Manufacturing and Resource efficiency award. Judges for this award commented on the progress the Company has made in terms of developing its people and systems towards achieving excellent manufacturing and resource efficiency performance.