We know Manufacturing

Let us demonstrate with this case study.


  • Multi-line manufacturing facility in NSW supplying construction industry
  • Highly competitive market on price, quality, delivery
  • Standard and custom product offerings


  • 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)


  • 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

Contact Maurice Driscoll Consulting and talk about the possibilities