Client Context

A regional fertiliser export facility believed it had reached its maximum output capacity. Any further growth was assumed to require significant capital investment to expand infrastructure.

The Challenge

The client sought to increase export volumes, improve berth utilisation, and reduce vessel turnaround time, while maintaining safety, cost control, and operational reliability.

Cornerstone’s Approach

Cornerstone carried out a full analysis of inventory management, vessel planning, berth allocation, and operational workflows. Special attention was paid to pre-arrival information exchange and communication gaps that were creating lost time and inefficiencies.

Based on this analysis, Cornerstone designed and implemented a Management Operating System built around the “Perfect Plan.”

Key actions included:

• Designing a centralised system for planning and managing vessel loading from the control room

• Implementing digital planning tools, KPIs, and performance reports to improve visibility and accountability

• Improving pre-arrival routines and communication with shipping companies

• Embedding continuous improvement and structured post-vessel review processes

Results Achieved

• Export volumes increased by 16% using existing assets

• Vessel loading completion times improved by 15–22%

• Improved vessel turnaround times increased berth availability

• Enhanced communication with shipping partners and improved staff morale

Client Impact

The facility unlocked significant additional capacity without capital expenditure. A subsequent technical and economic feasibility study provided a clear, data-backed roadmap for future step-change growth.