Situation:
Energy prices surged significantly in 2021, posing a major challenge to operational budgets. A review of 15 sites, accounting for 80% of the company’s energy usage, revealed opportunities for cost-saving through improved efficiency and operational adjustments.
Task:
Using Lean principles and tools, the team focused on optimizing energy usage without requiring new investments:
Actions:
1. Behavioural Changes: Encouraged shifts in operational habits to reduce energy waste.
2. Timing Adjustments: Altered the timing of pumping operations to maximize efficiency.
3. Lean Process Improvements: Streamlined workflows and processes to lower energy consumption.
Results:
The interventions delivered remarkable outcomes:
- £300,000 Saved in Just 3 Months: Achieved through operational and behavioural changes.
- Cost-Free Implementation: Improvements were made without any additional capital expenditure.
Key Lessons Learned:
- Leadership Drives Success: A strong top-down commitment to energy cost reduction was essential.
- Clear Communication is Key: A well-defined mission and consistent leadership messaging ensured team alignment.
- Lean Tools Add Value: Simple and practical tools solved complex energy-related problems.
- Behavioural Change is Transformative: Success depended on adopting sustainable operational habits through systems and Leader Standard Work (LSW).
- No Magic Wand Required: Significant savings were achieved without the need for expensive projects or technologies.