Standard Work (Structured Day)

Every Heavy Industry asset requires ongoing operations, maintenance and project work to maximise production and remain reliable. When this large site workforce (200+) began struggling with frontline worker utilization, the maintenance backlog grew exponentially and started to threaten plant reliability.
We started by developing a Value Stream Map to gain transparency of each day’s activities and identify the interactions between the Operations, Maintenance and Projects Teams. From this, we quantified the ‘technical limit’ achievable for a standard full shift to establish an ambitious target. Next, we spent a ‘Day in the Life of’ each site role to ‘Go-See’ the individual responsibilities in action and associated roadblocks. Finally, we established and rolled out a site wide Structured Day plan optimizing the overall throughput of the collective team.
Post rollout, worker utilization improved from 2.5-3hrs to 6.5+hrs per day for the same shift duration. The maintenance backlog all but disappeared and operations achieved 98+% compliance for their regular tasks. Project durations shortened saving millions in costs. Each shift is now planned, predictable, and efficiently executed.