Case studies

Relevant service: Business Transformation, Operational Excellence, Total Productive Manufacturing

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Lean excellence, engagement, success at leading utility company

About the Company

The organisation provides drinking water as well as the treatment and disposal of wastewater for its client base of over 3.5 million people. The organisations assets include over 25km of water main, 30km of sewers and 750+ sewage treatment works.

The Challenge

Faced with the need to increase reliability at their sites and improve workflow efficiency, our client embarked on a transformative journey. They aimed to enhance operational stability and streamline processes across multiple locations, seeking innovative solutions that aligned with their strategic goals.

Company

European Utility Company

Industry

Utilities & Construction

Size

Over 3500 employees

Revenue

+ £800 million (2023)

What We Did

Aligning Process

Maturity Assessment Development and Deployment: We developed a comprehensive maturity assessment to establish a clear baseline and set strategic goals for the Lean initiative. This assessment identified key areas for improvement and tailored our approach to the client's unique needs.
Specialist TPM Skills Development: Recognizing the importance of Total Productive Maintenance (TPM) in achieving reliability, we supported the development of specialist TPM skills in key areas. This training was instrumental in addressing specific reliability challenges at the client's sites.
Workflow Improvements in Procurement: We optimized workflow within the procurement team, specifically in handling incoming invoices. This led to significant cost savings and improved the working environment, contributing to increased productivity.

Engaging People

Leadership and Lean Training Program: We designed and rolled out an accredited Leadership and Lean training program across the organization. This empowered leaders and employees with the skills and knowledge necessary to drive continuous improvement.
Boosting Employee Engagement: A marked increase in employee morale and engagement was one of the most gratifying outcomes. Meeting attendance soared from 20% to 100% in just six weeks, reflecting a more motivated and involved workforce.

This appointment is great news for us as we start to broaden our deployment across the business, and deepen our approach in Waste and Water. S A Partners bring with them a wealth of understanding and knowledge, and we are looking forward to working with them. This broader approach will build on the success of the Lean RCM work, which will continue to form a key part of the overall programme. The Lean RCM teams are doing some great work, and we will ensure this continues to be delivered well across Water and Wastewater and this will form a key part of the programme going forward.

Mat Jackson

Lean Program Manager

Results

Remarkable Results

Reliability Enhancements through TPM: At two pilot sites, we implemented a robust TPM program, resulting in substantial cost savings of over £600K per site and equipping teams to replicate these improvements across other sites.
Maintenance Cost Reduction: At one site, targeted maintenance strategies led to a reduction in maintenance costs by over £150K, enhancing operational efficiency.
Problem-Solving at the Wastewater Plant: A Green Belt problem-solving exercise at a wastewater plant producing biogas corrected level control issues on the biogas holder, resulting in annual cost savings of over £100K.

Numerical Results

ROI: £1.5 million
Accredited 100 senior leaders in Lean Leadership
Trained over 1,350 Yellow Belts, 116 Green Belts, 23 Black Belts, and 5 Master Black Belts
Project deliverables: ~£25K cost savings, 5% improvement in other measures
Black Belt projects: ~£100K cost savings, 10% improvement in other deliverables

Framework

Welsh Water Framework 1

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