KÜMAŞ
In January 2012 one of Turkey's largest holding companies, Yıldız Holding, decided to acquire Kümaş Manyezit Sanayi A.Ş. – Turkey's leading producer and supplier of refractory products for steel, cement, glass, lime, non-ferrous and other industries. Furthermore, Kümaş is the largest producer of DBM, fused magnesite, refractory bricks, and mortars in Turkey, operating with around 1000 employees and a few hundred contractors.
KÜMAŞ Identifies Operational Efficiencies to Achieve Growth
Challenge
The day-to-day operations at Kümaş were dominated by a reactive "fire-fighting". In this way, accidents and incidents threatened the company's operations. Furthermore, the plant utilization and performance was below the holding company's expectations. Yildiz Holding chose dss+ to evaluate Energy Efficiency, Safety, Operations & Quality, Supply Chain, Maintenance & Reliability and Capital Effectiveness.
Solutions
During the first six-months, dss+ uncovered financial opportunities with a recurring value of USD 57 million. The capitalisation of this amount required changes at Kümaş. Before tackling improvement opportunities, it was important to establish a culture of safety and Operational Discipline by:
- Conducting interviews and focus groups
- Generating Profile of the workforce's critical values and attitudes to safety and operational excellence
- Conducting mirror workshops for senior management
- Generating a blueprint of business needs