The Top Ten Secrets of the World's Most Efficient Manufacturers

Presented by

Keith Findlay

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About us

• Keith Findlay and Productivity Leaders

• Companies that have benefited

• Values of success

• Pain Points Questionnaire

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Value of Success

• £6.9m savings within the automotive industry

• £130k savings within the supply chain industry

• Increase in utilisation of 25% in the supply chain industry

• 24% increase in performance in the drinks industry

• 83% increase in availability within the food/ingredient industry

• £287k savings within the medical & healthcare industry

• 12% increase in yield in the FMCG industry

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What’s in the Room?

99% of what we’re about to go through and discuss is already known by the people in this room

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Nicholas Chapman – Office of the Chief Economic Adviser

First estimates for 2014 suggest that output per hour in the UK was 20 percentage points

below the average for the rest of the major G7 advanced economies, the widest productivity

gap since comparable estimates began in 1991”“

US

Canada

Japan

France

Germany

UK

Italy

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“What do the following companies have in

common?”

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“What is it big companies like these DO to be successful?”

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Leading Global Brands – Top 10 Secrets

Quite simply – Invest, belief, energy and commitment

Plus having a company vision that incorporates a sound business/manufacturing strategy that is embedded into the culture of the company.

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What do they all have in common?

THEY ALL HAVE A PLAN WHICH SEE THEM THROUGH THE FOLLOWING FEW

YEARS

SOME COMPANIES HAVE CHOSEN TO CALL THIS THEIR 20/20 VISION OR MORE

APPROPRIATELY,HAVING A PLAN TO SEE THE BUSINESS THROUGH TO THE YEAR 2020

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Manufacturing Systems

The list of systems, philosophies, theories and practices is quite extensive.

Some of these, or all, can be implemented.Any of these, if applied with the correct mind-set, can deliver

the results that you planned

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Dispel some Myths

• It is natural for people to feel defensive towards any system that claims it can improve their work

• They take the subtext of a new process improvement initiative as an accusation that they are working poorly

• While natural, this defensive instinct, when taken to the extreme, can prevent us from developing our skills and making meaningful progress

• The purpose is to provide everyone in the organisation with an opportunity to better themselves and achieve greater success as a team

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#1Have the commitment to stick

with what you set out to do

If you had time to decide this was the plan then have the time to believe in it and let it grow/develop

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#2Believe that it will not go as well as planned but don’t be swayed

by this result

There are always ups and downs in any project delivery. Just because a programme is simple doesn’t omit it from being susceptible to problems

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#3Have realism about what will be accomplished but energise your

team for moreYour energy is key to your teams success. Set targets that are achievable but

with effort, and motivate your team to deliver more

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#4Be committed to the

programme, be visible and show your involvement

If the workforce see you are involved, then they will believe too

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#5When it doesn’t go to plan

(and it won’t!)commit to problem solving as a

way to recoverThis will empower your people to be accountable and responsible for the

outcome, both good and bad

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#6Celebrate your successes when

they happenAt each milestone of achievement get the teams who were involved and

celebrate with them. Invest in Reward and Recognition. It goes a long way to sustaining a programme.

This doesn’t need to involve payments of any kind either

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#7Commit to the Standard

– start as you mean to go onIf you enforce this, then this will become custom.

A habit exists after at least 21 occurrences of doing it repeatedly

– make it a habit

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Standards are a baseline for measuring change

This change cannot take place without creativity

Standards stimulate innovation

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#8Visually promote the message –

advertise your intentionsNever under estimate the power of visual reminders. It begins at saturation till adopted, then it tapers to memory joggers. People need reminding more than

they need to be told! Invest in it

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#9Know that this will need financial

investment of some kindEndeavour to release the funds to complete tasks in a timely manner.

Momentum is everything

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#10Be committed to the plan, believe that it will come to fruition, have the energy to see it through and

invest both financially and emotionally in making it happen

It is following this maxim that turns ‘Good’ to ‘Great’

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Pain Points of Manufacturing

• Sectors in the room

Logistics Construction

Manufacturing Automotive

Packaging Engineering

Food and Drink Printing

Chemicals Carpets and Upholstery

Control Systems Modular

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StatisticsEven though there are 12

different sectors within the room

the issues affecting

Productivity are similar and

shared

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Case Studies

Some examples of how expertly delivered projects can benefit the business

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Sector

Automotive

Supply Chain

Food & Drink

Healthcare

Packaging

Printing

Revenue

£19.3 Billion

£141 Million

£246 Million

£27.8 Million

£3.5 Million

£23.5 Million

Headcount

27.9k

>1000

4.9k

>300

>50

>150

Project & Saving

Six Sigma – £6.9 Million. 2 Projects – Wheels and Demister

Utilisation - £130k. Material Flow and Staff Utilisation

Performance – 24% increase. Autonomous Maintenance

Waste Reduction - £287k Savings. Raw Material Profile and Generation

Waste Reduction - £15k Savings. Change Over and Machine Setup

5S & Visual Factory - £9.7k Saving. Workplace Layout and Organisation

Case Studies

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• Lean Manufacturing – A full Manufacturing System overview

• Workplace Organisation – How to implement, Sustain and Audit

• BRC, ISO and Internal Management Systems

• Value Stream Management

• Change Management

Upcoming Events

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• Full Lean Manufacturing Systems Implementation

• Individual Elements such as;• 5S and Visual Factory

• Standardised Work Instructions

• Training

• Internal Auditing Standards (ISO, BRC, IMS)

• Total Professional Maintenance

• Capacity Analysis

• Value Stream Mapping

….. and many more

Services and Support

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Thank you.