Services
Cost reduction and production debottlenecking, end to end
One advisory practice that covers the whole cost base: materials, assets, energy and people. Each lever is tied to a number on your P&L.
01 · Production cost economics & margin defence
The pillar that decides whether a product is a business
Four steps take you from what your costs are to what to change first, with the money attached.
- 1
Cost structure teardown
Raw material contributions and purity effects, energy and utilities, catalysts and consumables, manpower, effluent treatment and overheads, taken apart element by element.
- 2
Granular variance analytics
Design basis against actuals, by unit and by cost element, to find where margin leaks rather than where it happens to be reported.
- 3
Cost curve & sensitivity
Cost per tonne at part load, design load and nameplate, and how it moves with feedstock price, energy tariff, yield, catalyst life and uptime.
- 4
Corrective levers
A ranked list of operational and design changes with the money attached to each, so the cheapest recovery happens first.
02 · Operational levers
OEE and line balancing
More good output from the same assets, people and power.
Downtime reduction (TPM)
Total Productive Maintenance frameworks that curb unplanned equipment failures and speed up changeovers.
Cycle time optimisation
Remove micro-stoppages and bottlenecks across sequential process stages to lift overall line throughput.
Yield & scrap minimisation
Find the root causes of process defects to cut rework loops, raw material waste and lost machine hours.
Energy & utility efficiency
Audit power loads during peak intervals and optimise idle-state consumption across high-draw machinery.
03 · Material economics
Sourcing rationalisation and working capital
Materials are usually the largest share of cost, so every percentage point here moves the bottom line.
Supplier consolidation
Pool purchasing volume across plant sites to negotiate tier-1 volume discounts and standard pricing caps.
Value engineering (VAVE)
Redesign components or substitute equivalent technical materials to reduce input cost without compromising reliability.
Inventory carrying costs
Right-size safety stock, move to lean pull-based replenishment and release working capital locked in obsolete buffers.
04 · Beyond cost
Capabilities built over 38 years of running plants
Energy management & sustainability
Specific energy consumption benchmarking, heat recovery, utility optimisation and decarbonisation roadmaps that pay for themselves.
Process debottlenecking
Unlock rated, and beyond-rated, capacity from existing lines before committing to new capital.
Greenfield & expansion projects
Equipment selection, techno-commercial evaluation of global vendors, erection and commissioning to rated capacity.
Leadership & capability building
Upskilling workshops and Kaizen circles so your teams sustain lean discipline long after the engagement.
Talk to us
Ready to capture your margin potential?
A short conversation about your plant is the best place to start. Reach out directly, whichever way suits you.