Increase your productivity and reduce costs in 6 Weeks and sustain over 6 years
To truly improve operational performance you need the right tools and techniques and the commitment from your employees. Maximising the uptime, reliability and output of your plant and equipment is crucial to the overall performance and profitability of your business.
Too many continuous improvement projects focus solely on gaining efficiencies without challenging the basic assumptions of what is being done. MCP’s approach relies on working with people at all levels in the organisation from shopfloor to topfloor to:
- Reduce equipment downtime
- Improve production output
- Enhance the skills of the workforce
MCP helped us with our productivity improvement programme, covering various lean techniques and continuous improvement tools to improve manufacturing performance and deliver skills enhancement for all our operators.
Manufacturing Improvements with MCP
At MCP we do things differently, focusing on”optimisation” so that we can help you customise how and where continuous improvement is applied. We can then deliver manufacturing improvements through a structured programme which starts to produce real results in just 6 weeks. We work with you to:
- Reduce manufacturing costs
- Improve operational efficiency
- Implement Lean
- Improve layout of the plant
- Deliver Manufacturing and Asset Care Excellence.
MCP’s Manufacturing Cost Reduction Programme
Do you need to improve production output and reduce manufacturing cost within 6-8 weeks? MCP’s cost reduction programme will deliver the following improvements through a structured programme:
- 20% + increase in Plant Output
- Quality at greater than 98%
- Minimum 10% reduction in Cost
The 10 week production improvement programme, which delivers results after 6-8 weeks involves:
- Manufacturing assessment – Week 1
- Implementation Plan – Week 1
- Implementation – Weeks 2 to 10
- Roll out to different production lines and areas – Week 10 onwards
A typical cost reduction programme will include:
- Manufacturing Assessment
- Training in Lean Manufacturing, lean six sigma, Kaizen and TPM principles
- Shopfloor coaching and support
- Champion projects and work place assessment
- Extension to other areas of the plant by champions
The programme is designed for:
- Delivery within existing working patterns
- Minimal release of staff from day to day roles
- Continuous Improvement and Development
- Early identification and delivery of improvements
Typical results delivered by our clients using the programme include:
- Savings of £700,000 generated in initial 10 week programme
- Savings of £2.7m identified and committed to for the whole of the site
- Increase in OEE from 30% to 80%
- 29% increase in line output
- Increase in OEE on pilot lines to 60%
- Reduction of 3 people per shift from the cell
- Increase in first pass yield from 74% to 98%
How do I reduce my operational costs?
Email firstname.lastname@example.org or call now for more details on +44 (0) 121 506 9034
A dozen tips to improve the likelihood of CI success – taken from the Works Management Article
Over the years there have been many valiant attempts to make continuous improvement and lean manufacturing easier to understand.
There are 12 basic rules that should significantly boost your chances of CI success:
- Accept that applying a CI initiative will probably disrupt your existing processes, so prepare your employees for the changes heading their way.
- Involve your team in the implementation – getting people on board is the most important element in a CI programme. Without this, you will fail to change the culture and the changes that are made will have no chance to bed in.
- Tailor the needs of the programme to your specific circumstances – a one-size-fits-all approach simply won’t work.
- Don’t implement big change fast unless you are fighting for survival. Total business process re-engineering is risky; gradual improvement gives you greater control.
- Recognise that some initiatives will fail. Adopt the Fred Astaire principle: Pick yourself up, dust yourself off, and start all over again.
Be patient; change won’t happen overnight. MCP’s Phil Tugwell says: “Any programme like this is about behaviour change, it is about putting disciplines into the organisation, and it is about getting that way of thinking into the DNA of the business so that it becomes habitual. That takes 18 months to three years.”
- Standardise your practices to make sure everyone is on the same page and a process is repeatable… and document your solutions.
- Don’t just focus internally – too many companies decide they must get their own house in order before they look at their suppliers; this is a mistake. Examine your supplier relationships and fix them if they are broken.
- Review your progress constantly. Adopt the PDCA cycle – plan, do, check, act (or adapt).
- Measure both key performance indicators and the practices (tools and behaviours) that you put in place and ensure they are sustainable.
- Manage people’s expectations. If they anticipate too much they will be disappointed; too little and they won’t achieve enough.
- Communicate progress constantly in every way possible – through andon boards, meetings, newsletters, and so on.