Radical improvement

Jun 27, 2013Download as PPTX, PDF0 likes414 views

This document discusses a radical improvement project to improve the capacity and efficiency of a machining cell. Key aspects of the project included collecting data, mapping the current process flow, redesigning the cell layout to improve flow, and implementing projects to minimize downtime and wear rates. As a result of these improvements, productivity was maximized and a cost saving of approximately £340,000 was achieved, utilization increased to 90%, downtime decreased to 20%, and quality improved.

Capacity Improvement
Radical Improvement
As part our approach to changing a Culture we knew how important momentum and
results were; so a key delivery of the CI team was ‘Radical improvement’.
As part of managing a CI team one of the things we focussed on was high priority
changes, which also formed a base for team member’s development and motivation
through autonomy. One of these projects is detailed below, led by a key member of my
team;
• Improvement project on a machining cell to improve efficiency on a target area for
business growth. The improvements were to maximise productivity through
downtime minimisation and wear rates. A cost saving of approx. £340,000.

Machining Department
Dramatically improve it’s capacity.
10Machine Department
50%Utilisation
HighReject rate
40%
Downtime

Radically improve
Capacity and design for effectiveness
• One of the things we started to do was create an injection of enthusiasm for improvement, which started
with data collection and ideas for improvement. One of these projects led by an engineer would show
dramatic cost savings.
• Our main focus was cell design; spaghetti diagrams and value stream mapping showed a very poor flow
and opportunities around inventory and machinery downtime.
• We also kicked off key projects between engineers and team members, that came out of brainstorming
and data collection activities; these were key for involvement.
Data
Collection
Team
Work
Enthusiasm
and
Involvement
Value Stream
Mapping, Flow
diagrams,
Continuous
Improvement
Engineering.

Capacity Improvement
And much more
• Together with the team we dramatically improved the cells flow and machinery utilisation.
• The improvement not only boosted morale but also ensured they could meet demands of higher
customer demand to boost profit.
• The teamwork between engineering and production dramatically improved and continues today.
• The projects and outcomes included those focussed around up skilling team members as well as
motivation through autonomy.
£340,000
Cost saving
90%Utilisation
Best
improved
quality
20%
Downtime

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Radical improvement

1. Capacity Improvement Radical Improvement As part our approach to changing a Culture we knew how important momentum and results were; so a key delivery of the CI team was ‘Radical improvement’. As part of managing a CI team one of the things we focussed on was high priority changes, which also formed a base for team member’s development and motivation through autonomy. One of these projects is detailed below, led by a key member of my team; • Improvement project on a machining cell to improve efficiency on a target area for business growth. The improvements were to maximise productivity through downtime minimisation and wear rates. A cost saving of approx. £340,000.

2. Machining Department Dramatically improve it’s capacity. 10Machine Department 50%Utilisation HighReject rate 40% Downtime

3. Radically improve Capacity and design for effectiveness • One of the things we started to do was create an injection of enthusiasm for improvement, which started with data collection and ideas for improvement. One of these projects led by an engineer would show dramatic cost savings. • Our main focus was cell design; spaghetti diagrams and value stream mapping showed a very poor flow and opportunities around inventory and machinery downtime. • We also kicked off key projects between engineers and team members, that came out of brainstorming and data collection activities; these were key for involvement. Data Collection Team Work Enthusiasm and Involvement Value Stream Mapping, Flow diagrams, Continuous Improvement Engineering.

4. Capacity Improvement And much more • Together with the team we dramatically improved the cells flow and machinery utilisation. • The improvement not only boosted morale but also ensured they could meet demands of higher customer demand to boost profit. • The teamwork between engineering and production dramatically improved and continues today. • The projects and outcomes included those focussed around up skilling team members as well as motivation through autonomy. £340,000 Cost saving 90%Utilisation Best improved quality 20% Downtime

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Radical improvement

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