Towards World Class Manufacturing

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Onsite Insights Company visits across the UK Best practice visits to award-winning companies across the UK

description

Presentation to the Northern Manufacturing Exhibition 2014

Transcript of Towards World Class Manufacturing

Page 1: Towards World Class Manufacturing

Onsite InsightsCompany visits across the UK

Best practice visits to award-winning companies

across the UK

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Onsite InsightsCompany visits across the UK

Best Practice and World Class Manufacturing

Ailsa Kaye Director

Onsite Insights

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Onsite InsightsCompany visits across the UK

• Onsite Insights• National Programme

• Established 2004

• 10,000 Visitors

• +100 Visits each year

• Insights-Training.com

• International Partners• Canada & North America• Germany• France• Italy• Austria• Australia

“Tell me and I'll forget; Show me and I may remember; Involve me and I'll understand.”

Chinese proverb

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Onsite InsightsCompany visits across the UK

World Class companies are those that demonstrate industry best practice

They are generally assumed to be those that demonstrate industry best practice in Quality, Price, Delivery Speed, Reliability, Flexibility and Innovation

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Onsite InsightsCompany visits across the UK

World Class Manufacturing - Framework

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

WCM – utilises a range of tools:

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

Key Point

Start from a

theoretically

ideal situation

Key Point

Start from a

theoretically

ideal situation

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

• Customer Driven

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Onsite InsightsCompany visits across the UK

• Financial Justification

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Onsite InsightsCompany visits across the UK

• Better working conditions =increased staff satisfaction & loyalty• Motivated employees – look for improvement & are advocates

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

Benchmarking

A CONTINUOUS process of measuring not only financial data, but also products, services and practices against competitors or ‘best-in-class”.

Common metrics

• Customer Satisfaction (NPS)• Quality• Cost• Delivery• Safety• Supplier Performance• Productivity

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Onsite InsightsCompany visits across the UK

10 World Class Manufacturing Sites

1. Jaguar Land Rover - Halewood

2. Mars Drinks - Basingstoke

3. Pfizer - Havant

4. Milliken - Bury

5. Entek International - Newcastle-Upon-Tyne

6. BAe Systems - Rochester

7. Fujifilm Speciality Ink Systems - Broadstairs

8. Mitsubishi Electric Air Conditioning – Livingstone

9. Agfa - Leeds

10.Toyota - Deeside

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Onsite InsightsCompany visits across the UK

World Class Journey • Pre 1998:

• poor industrial relations,

• quality and productivity uncompetitive

• poor morale

• Cultural Transformation• Burning platform – change or close

• Create a common vision & purpose

• Lean & CI heart of everything they do

• Quality and the pursuit of excellence in everything they do

• Today:• Competing on a global level

• JLRs best scoring plant & Centre for excellence

• Home to a motivated, skilled and flexible workforce

• Growing!!

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Onsite InsightsCompany visits across the UK

Group Member

Group Leader

Supvr & Eng

Supt

MgrGroup Member

Group Leader

Supvr & Eng

Supt

Mgr

Challenge to change the Management methods D

irect

ive

Sup

porti

ve

Using Policy Deployment as an INPUT Driver to achieve OUTPUTS

OUTPUTS = (Safety, Quality, Delivery, Cost, People/Environment)

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Onsite InsightsCompany visits across the UK

World Class Journey

• Building Effective Teams with Shared Principles(Mission Directed Work Teams)

• Lean Tools & Techniques• Five S• Seven Wastes• TPM

Best Ideas

• Mission Directed Work Teams• Shared Principles

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Onsite InsightsCompany visits across the UK

World Class Journey

• Competition from within a global company

• Creating a centre of excellence at Havant

• Logistics and Distribution – Innovation

• Driving improvement globally

Best Ideas!

• Own It! – translating corporate directives at a local level

• Create a Centre of Excellence

• Hoshin Kanri

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

World Class Journey

• Focus on Lean, OEE and process excellence

• Focus on Leading Technologies

• Supply Chain Excellence

• Engagement

Best Ideas!

• Focus on the whole organisation – not just manufacturing

• Engage employees and suppliers

PHILOSOPHY

"Operational excellence secures the present.

Innovation excellence secures the future.”

Roger Milliken

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Onsite InsightsCompany visits across the UK

World Class Journey

• Business transformation 5 years ago loss-making

• 2013: + 30% profit

• Total commitment to lean and continuous improvement.

• 2012 Winner of Best Factory People Management; Best Process Plant and Innovation and Design.

Best

• Culture transformation through Lean/CI – a total engagement at all levels.

• Effective and open communication

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Onsite InsightsCompany visits across the UK

World Class Journey

• Began in 2006

• 13 Queens Awards for Innovation

• 8 Queens Awards for Export

• Quality @ 99.5%

• Cost Reduction 10%

• Productivity Improvement 50%

Best Ideas

• Get the Culture Right First

• Aim for World Class – Shingo!

• Innovate

• Integration of all office staff onto the shop floor

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

World Class Journey

• Began in 2005

• Home grown programme of CI & Quality

• RFT improved from 45% to 95%

• Waste reduction £1.1 million

Best Ideas!

• Personalise your system – make it right for YOUR business

• Focus on communication

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Onsite InsightsCompany visits across the UK

World Class Journey

• Driven by the latest technology

• Lean as ‘a way of life’

• Environmental leadership

• Process & continuous improvement

Best Ideas

• Driving innovation within their industry• Leading environmental change

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Onsite InsightsCompany visits across the UK

World Class Journey

• Integrated Management Systems (ISO standards)

• Sustainability & Efficiency• Safety Management

Best Idea

• Sustainability • Safety First

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Onsite InsightsCompany visits across the UK

World Class Journey

• Deeside engine plant ‘Centre of Excellence’ – supplying Europe, Japan and South Africa

• Admired, copied but never bettered – why improved daily

• Foundation of Toyota’s success isn’t the process control it is employee engagement

• Three C’s Challenge, Creativity, Courage

• Respect for People

• Mutual Trust – mutual responsibility

• No fear no blame

• Ownership at all levels

• Best IdeasToyota Way (People) and TPS

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Onsite InsightsCompany visits across the UK

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Onsite InsightsCompany visits across the UK

Best Practice & WCM requires:

1. A compelling and shared vision – Operational alignment

2. CI Culture – engaged and motivated employees

3. Process excellence (using tools such as lean and six sigma)

4. Innovation at the core of business

5. A customer-centric organisation

6. Excellence in Design (D4M)

7. Results Driven – Measure what matters – outputs!

8. An ethical and ‘authentic’ approach

9. Environmental & sustainable management

10.Continuous pursuit of improvement

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Onsite InsightsCompany visits across the UK

Upcoming Visits

8 October Silent Gliss, Broadstairs

8 October Mars Chocolate, Slough

9 October Milliken, Bury

14 October Happy, London

15 October Eaton Crouse-Hinds, Sheerness

21 October Agfa, Leeds

30 October Jaguar Land Rover, Halewood

3 Nov Toyota, Deeside

5 Nov Buhler Sortex, London

10 Nov Nissan, Sunderland

12 Nov Double H Nurseries, Lymington

12 Nov BAE Systems, Rochester