• Alexander Proudfoot Alexander Proudfoot

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    Mining and Metals Practice

    Alexander Proudfoot helps companies better execute their plans and strategies to deliver substantial improvements in performance and profitability.
  • Building Materials

    Adding Value through Disciplined Execution

    The building materials industry is facing new challenges globally, creating a need for analysis and insight. Companies must begin to assess their competitiveness while developing new growth strategies to be successful in today's ever-changing landscape.

    Typical Results

    Results you can count on
    What we can help you achieve

     

    • Cost per ton decrease 15%
    • Direct labor productivity improvement 25%
    • Material handled per hour improvement 19%
    • Overtime reduction 72%
    • On-hand inventory days reduction 67%
    • Energy expense reduction 15%
    • Scrap reduction 18%
    • Throughput improvement 25%
    • Accident rate fell 50%
    • Energy usage reduction from 5-15%
    Additional Resources

    What we do

    Your partner for disciplined execution
    Helping companies elevate operational and financial performance

    Proudfoot partners with building material companies to help them compete more effectively in an increasingly competitive marketplace.  No stranger to market volatility, we help these companies drive the rapid execution of their corporate strategy – improving the top-line, strengthening their resilience, and preparing them for future growth.

    • Driving rapid change
    • Delivering a tailored approach
    The key to our success is our ability to drive the rapid and effective execution of corporate strategy throughout the organization, while adding pace, predictability and control.
    Our approach is tailored and adapted to the needs and strengths of each client from safety and energy usage to working capital, asset utilization or productivity. This allows our clients to overcome any barriers to change and provide greater certainty of a step-change in performance.

    Client Results

    What our clients say
    "As we have grown, we have found ourselves challenged to gain efficiencies while maintaining this culture. In a relatively short period of time, Proudfoot has been able to identify opportunities and help us execute a plan. They have exceeded our expectations and are helping us realize the economies of scale we need to achieve. The system they are helping us to implement will allow us to accommodate growth and increase profitability."
    Chief Operating Officer, Allied Building Products
    "With Proudfoot's help we have done in six to eight months what would have taken us two to three years on our own."
    Group Vice President and GM, CertainTeed
    Project Results - Successful Past Projects
    • Operational performance
    • Cost reduction
    • Operating practices
    Objective: As one of the world leaders in building materials, the company undertook a significant restructure of operations in an attempt to improve efficiency. The client faced considerable operational challenges, which were hampering its efforts to achieve its targets so she turned to Proudfoot to help drive greater resource utilization, increase throughput and cut fixed and variable costs.

    Approach: Proudfoot conducted a detailed analysis of the operations and uncovered several shortcomings that impacted efficiency. Joint client-Proudfoot teams provided management with appropriate tools and processes to improve planning and control production and increase throughput. Also, the teams worked on purchasing by revising the product and service categories at a national level in order to consolidate them and better align them with the organization objectives. Finally, the teams focused on delivering a blueprint of the new cement organization and a road map for installation in other areas.

    Results: Within six months, operation performance was transformed. The teams achieved a 6% purchasing cost reduction and a 185% quarry production increase. In addition, the project increased effective working time and improved skills, behaviors and management tools.
    Objective: One of the world's largest manufacturers of building materials found that some of their costs were running 40% above those of their competitors. In order to remedy this situation, the company brought in Proudfoot.

    Approach: The project hinged around a new system that ensured managers were getting the necessary information to make accurate and timely decisions. A behavioral model was designed that placed focus on greater supervisory control; increasing their time on the floor and actively supervising people. The team also provided short interval controls to the first-line supervisors to improve their planning and scheduling, and increase productivity. Master schedules were also implemented to balance resources better.

    Results: The project achieved a 46% contractor cost reduction and 20% cost savings across all 39 plants, earning a total savings of EUR 53.8 million. It also greatly improved time between failures from 182 hours to 214 hours.
    Objective: The client was hoping to establish world-class operating practices by overhauling quarry operations in order to reduce costs, improve maintenance procedures and increase uptime and throughput.

    Approach: Standardized working practices applicable to both management and contractors, were created. Proudfoot worked with local site management to overhaul the entire mining process, including blasting, excavation, loading, hauling and crushing. The teams also worked to eliminate inefficiencies, reduce cycle times, cut idle times and improve crusher productivity. Coaching for management on better negotiating with suppliers was also implemented.

    Results: The installation exceeded planned improvements by more than 23%, while also providing a template that the company could apply in hundreds of additional quarries. The company also experienced a 10% cost reduction.

    Areas of impact

    Expertise across all operational areas
    Alexander Proudfoot has more than 70 years of experience delivering operational results across various industries and operational areas. Allow us to tap into this knowledge to help you maximize your operations.
    • Productivity
    • Strategic Procurement
    • Safety
    Improving productivity and increasing organizational effectiveness can deliver a real step-change in business performance, enabling companies to gain a valuable competitive advantage over rivals.

    Alexander Proudfoot has been synonymous with productivity improvements and operational effectiveness since 1946.  We use a unique methodology for measuring productivity, first developed by our founder and continuously updated and refined ever since.
    Our approach to supplier relationship management is collaborative in nature and yields better pricing and superior results, which our clients translate directly into a competitive advantage in the marketplace.  By combining our world class execution experience with an unparalleled change-management approach, we deliver a world-class strategic procurement infrastructure that sets our clients apart from the competition.
    Some managers fear that safety comes at the expense of productivity, but we have found the opposite to be the case. Productive and efficient mines are also safer mines. Active supervision, clearly established roles and responsibilities, preventative maintenance, active reporting and resolution of near misses and policies that reward desired behaviors all play a part in making for a safe mine as well as a productive one.
    Other Areas
    • Throughput
    • Maintenance
    • Operations
    • Raw materials
    • Scrap
    • Labor, resource and asset utilization
    • Inventory
    • Machine downtime
    • Organizational effectiveness
    • Warehouse
    • Working Capital
    • Overtime
    • Contractors
    • Operating systems
    • Safety