Manufacturing
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Let us demonstrate with this case study.
Client
- Multi-line manufacturing facility in NSW supplying construction industry
- Highly competitive market on price, quality, delivery
- Standard and custom product offerings
Issues
- Inconsistent quality and delivery times
- Very high level of workforce dissatisfaction
- Costs well above industry average; safety performance much less than satisfactory
Key Methodology
- Effective Questioning Conversations
- ‘5 Why?’ Root Cause Analysis (RCA)
Resolution
- Established Root Cause Analysis teams for each line
- 60% workforce volunteering rate to be part of teams
- Increased two-way communication between Engineering/Technical and workforce
- Just in Time delivery of orders created and advantaged
Changeout times reduced by > 50%
Outcomes over 12 months
- Changeout times reduced by > 50%
- Cost reductions reached 175% of target; safety performance improved
- Yield increased by 3% – a multi million dollar return
- Warehouse order backlog resolved and monitored
- Workforce input identified and resolved quality issues on each line
- RCA teams became a permanent part of Operations