Towards World Class Manufacturing
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Transcript of Towards World Class Manufacturing
Onsite InsightsCompany visits across the UK
Best practice visits to award-winning companies
across the UK
Onsite InsightsCompany visits across the UK
Best Practice and World Class Manufacturing
Ailsa Kaye Director
Onsite Insights
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
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
Onsite InsightsCompany visits across the UK
World Class Manufacturing - Framework
Onsite InsightsCompany visits across the UK
Onsite InsightsCompany visits across the UK
WCM – utilises a range of tools:
Onsite InsightsCompany visits across the UK
Onsite InsightsCompany visits across the UK
Key Point
Start from a
theoretically
ideal situation
Key Point
Start from a
theoretically
ideal situation
Onsite InsightsCompany visits across the UK
Onsite InsightsCompany visits across the UK
• Customer Driven
Onsite InsightsCompany visits across the UK
• Financial Justification
Onsite InsightsCompany visits across the UK
• Better working conditions =increased staff satisfaction & loyalty• Motivated employees – look for improvement & are advocates
Onsite InsightsCompany visits across the UK
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
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
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!!
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)
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
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
Onsite InsightsCompany visits across the UK
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
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
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
Onsite InsightsCompany visits across the UK
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
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
Onsite InsightsCompany visits across the UK
World Class Journey
• Integrated Management Systems (ISO standards)
• Sustainability & Efficiency• Safety Management
Best Idea
• Sustainability • Safety First
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
Onsite InsightsCompany visits across the UK
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
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