validus management consultancy UK

Utilities Case Study

BNFL Sellafield

NII's critical review of 1999 had to be addressed
Established new manufacturing support group and implemented 19 improvement initiatives


The Connections business within a major multi-utility service provider, covering both Regulated and Competitive connections. Multi-site business with a total of 18 Regulated teams and 14 Competitive teams across 7 locations


Following the NII's critical review of 1999, need to:
  • Strengthen the manufacturing capability on site and introducing basic manufacturing disciplines
  • Improve overall site performance and remove specific bottlenecks
  • Undertake improvement activity within the unique culture at BNFL Sellafield


  • Established a new internal department, the Manufacturing Support Group (MSG), up to full strength over 2 years (50 FTE's).
  • Implemented the Overall Equipment Effectiveness (OEE) measure as the key driver for performance improvement
  • Constructed a plant and site wide OEE databases to enable analysis, evaluation and interpretation of OEE data
  • Phased transfer of responsibility from consultants to the MSG
  • Established ongoing management review and improvement infrastructures
  • Established improvement team structures, targets, activity and management framework
  • Applied Six Sigma, Kaizan and Lean Manufacturing approaches to drive improvement activities across the site
  • Integrated improvement activity with Sales Order Processing
  • Developed the new relationships between the MSG, and others on site to ensure a quality, value added service


  • MSG now well established
  • OEE measure successfully implemented in 12 major plant areas
  • A total of 19 separate improvement initiatives underway
  • MSG staff actively and confidently extended the OEE roll-out across the balance of the site and facilitated improvement team activity
  • Breaking down the 'silo-mentality' that had historically been a feature of the culture at Sellafield
  • Improved control of operations
  • NII's increased confidence in BNFL's ability to deliver operational performance