Case Study Kaizen Review Celebrates Cement Success

Situation /Driver:

  • A team of Cement Australia and TasRail employees met over two days in November to review progress of the cement train operation since implementing a number of improvements implemented as a result at the Cement Train Lean Kaizen event conducted in mid 2016.
  • Desired Future State from the original Kaizen event):
  • Increased tonnes per train.
  • Reduction of carry-back after unloading.
  • Improved run times between Devonport and Railton.
  • The Approach Undertaken and
  • Solutions Implemented:
  • Last year’s project team identified 26 separate improvements that have been implemented during the past 18 months.

Benefits Achieved:

  • November’s review workshop identified a number of key achievements, including:
  • An additional 114,164 tonnes of cement hauled in the 2016/17 financial year compared to the previous year;
  • An average, additional 21.33 tonnes per train loaded in the 2016/17 financial year compared to the previous year;
  • A decrease in carry back from an average 45 tonnes per train to 23 tonnes per train; and
  • Reducing the time taken to receive a track warrant from Network Access from 19 minutes to approximately 4 minutes.
  • CA relies on our ability to operate an efficient and continuous service delivering product to their silos in Devonport. Any opportunity we can identify to improve that service is good for CA and good for TasRail. I would like to congratulate the 2016 Project Team, our train drivers and the CA Silo Operators for their efforts over the last 16 months to deliver these results.” said Freight Services GM, Bob Parton.

Future Plans:

  • As part of continuous improvement efforts the team who participated in the recent review also identified several opportunities for continued improvement moving forward and these will be implemented during 2018.
  • Cement Australia Production Manager Garry Bissett commended those involved in the work done to date and highlighted the importance of TasRail’s service to their business. “We are looking forward to continuing to partner with TasRail to achieve optimal results with the cement train in the future,” he said.