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Posts Tagged ‘world class manufacturing’

TPM Principles & Application

Saturday, June 11th, 2011

Back in 2009, KCTS starting blogging about Total Productive Maintenance which has been a core system within KCTS since it started in 1998.

Read it again below:

TPM Principles & Application

What is it?

TPM means Total Productive Maintenance. TPM is about involving everyone in creating and sustaining the necessary standards in their own areas. The standards must continually challenge the organisation to get better results as fast as possible.

A number of techniques are used to get the involvement and change in standards which are needed to deliver better results.

The techniques are often shown as a “TPM Temple”. This demonstrates that the techniques all aim to reduce Losses & Wastes, often measured by OEE, and apply to any organisation no matter the structure or products. Each technique has a number of Key Steps which need to be done to get the involvement and change in standards which are needed to deliver better results. The techniques focused upon within this programme are:

•    Focused Improvement, also called Continuous Improvement or Kaizen
•    Autonomous Maintenance
•    Professional Maintenance, also called Condition Based & Planned Maintenance
•    5S, also called Workplace Organisation
•    TPM Loss & Waste programme including OEE, Overall Equipment Effectiveness

Other techniques which may be applied as part of TPM are:
•    Safety, Health & Environment, reducing accidents, illness & emissions
•    Training & Education, improving consistency and delivery of knowledge
•    Early Management, improving the way new products and process are introduced
•    Quality Maintenance, reducing quality problems
•    TPM in Administration, involving people who work in offices and helping change standards in the offices to deliver better results

TPM aims to reduce losses to ZERO. This can be an extremely tough target for some losses, but ultimately satisfying for the people where the losses occur when achieved.

When to use it?

Identification of the type of problem can help work out the plan on how to solve it. Autonomous Maintenance and Professional Maintenance can eliminate sporadic problems by getting reliability back into the process, the area or the activities. Quality Maintenance will improve reliability of the process further to reduce quality defects. Other parts of TPM that can eliminate chronic problems include Focused Improvement, 5S Workplace Organisation and Training & Education.

What does it achieve?

Ownership of problems is only possible when people within the area, or activity, where the problem occurs can be involved in its elimination. TPM focuses people on creating and updating standards to share learning and tackle common problems. TPM delivers results faster than tackling problems in an unstructured way.

TPM aims to reduce losses to ZERO.

Key steps:

1.    Visit the area, or observe the activity, and investigate the problem
2.    If the problem relates to Safety, Illness or Emissions, select Safety, Health & Environment techniques to eliminate the problem.
3.    If the problem occurs regularly, every shift or every day or every week the problem is Chronic
4.    Select Focused Improvement, 5S or Training & Education when there are Chronic problems
5.    If the problem occurs regularly, every month or every year or every few years the problem is Sporadic
6.    Select Autonomous Maintenance and Professional Maintenance or Quality Maintenance as an improvement tool when there are Sporadic problems.
7.    Visit the area, or observe the activity, and check the problem has been eliminated

Variations:

•    Most people do not mind changing, but most people mind being changed. The way that people are involved is crucial and standards must be written by those who work within the area, or activity. These standards must be communicated and reviewed by the other people who also work within the area, or activity.

Press Release – Instructor Course 14

Monday, October 25th, 2010
Written by Lee Oxton

PRESS RELEASE

World Class Training being held in Toronto

Wirral, UK. 25th October 2010.

UK based specialist business improvement training company; Kaizen Consultancy & Training Services (KCTS) are currently delivering their flag-ship Total Productive Maintenance (TPM) Instructor Course to world leading plasterboard manufacturer, Saint Gobain Gyproc. The two week event is being held in Toronto, Canada and involves thirty two senior managers and other personnel representing Saint Gobain Gyproc plants from around the World.

Saint Gobain Gyproc is now into their ninth year of a World Class Manufacturing programme which encompasses 68 manufacturing facilities in 54 countries. The Instructor Course is the fourteenth event held to date, all of which have been delivered by Kaizen Consultancy & Training Services.

Delegates who participate in this intense training will qualify as Instructors in TPM once they have gone back to their respective plants and led improvement projects.  They are then reviewed in areas such as; 5S, Problem Solving, Autonomous Maintenance and Professional Maintenance 100 days later.

As a result of this training outputs have increased by up to 40%, product quality has improved, safety performance is better and costs have been substantially reduced. Saint Gobain Gyproc have made an estimated 95 Million Euro in efficiency cost savings and are well underway to achieving Silver Plant status within their World Class Manufacturing model, throughout the Global Gyproc division.

About KCTS

KCTS are an international training & consultancy provider of specialist World Class Manufacturing (WCM) standards. Delivering TPM, Lean, Change Management and Policy Deployment programmes to the manufacturing and service industries Worldwide. Through these proven methodologies KCTS can reduce costs by identifying and removing losses within a process or value stream. For further information regarding this press release or KCTS, please contact; KCTS on 0151 608 9036 or visit www.kcts.co.uk.

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Press Release – M.I.C.K 2

Wednesday, July 28th, 2010

PRESS RELEASE

Improved Problem & Fault Finding Capability

KCTS’s “Mobile Investigation Camera Kit” (MICK) has been Factory tested.

Wirral, UK. 26th July 2010.

After successfully completing upgrading our MICK to MICK 2, the latest model has now been fully testing in a live factory environment. Matthew Treby (Technical Consultant) has been to a local factory and put MICK 2 through its paces to evaluate the system and ensure the quality of the product and picture was perfect.

The unit has had a complete revamp after taking into account feedback from people who have used the previous MICK kit. These improvements include a completely new camera cabling system that is lighter, more flexible and can run for longer lengths. The cases have also been improved so they are more portable, hardwearing and the components split into several flight cases, allowing easier access and lighter to carry. The picture quality from the cameras has been improved allowing sharper and clearer images to be recorded and played back at various speeds. To further enhance the viewing experience the monitor size has also been increased. Due to the improved image quality we have upgraded the storage capability, as well as making it easier to get data from the unit by DVD and memory stick. Finally MICK 2 is easier to use, than the previous MICK, with the inclusion of a mouse and remote control.

The system still retains it core fundamental components of clamps, arms and tripods, as these are essential in order to position the cameras accurately in awkward positions. Despite all the many improvements that have been done, MICK 2 can still function at 110 Volts or 240 Volts so can be used worldwide with no modifications. The MICK 2 system will be on sale from September.

About KCTS

KCTS are located on the Wirral peninsula and are an international training & consultancy provider of specialist World Class Manufacturing (WCM) standards. Delivering TPM, Lean, Change Management and Policy Deployment programmes to the manufacturing and service industries Worldwide. Through these proven methodologies KCTS can reduce costs by identifying and removing losses within a process or value stream. For further information regarding this press release or KCTS, please contact; KCTS on 0151 608 9036 or visit www.kcts.co.uk

END

Lean Training

Thursday, May 20th, 2010

PRESS RELEASE

KCTS completes another successful TPM Instructor Course with all 32 delegates passing…

All newly appointed TPM Instructors now move on to successfully implement continuous improvement projects in their own locations.

Wirral, UK. 19th May 2010.

After successfully completing their twenty third World Class Manufacturing Instructor course, Wirral specialist training provider Kaizen Consultancy & Training Services are proud to announce another record beating result. All thirty two delegates who underwent the intense two week training course in Total Productive Maintenance have passed with flying colours.

The TPM Instructor Course which was held on behalf of global leading building materials manufacturer, Saint Gobain Gyproc is the thirteenth of its kind to be conducted as part of their journey to World Class. The training is the highest level TPM training that can be achieved and covers industry specific topics such as; problem solving, people development, leadership, maintenance, health & Safety, quality and workplace organisation.

‘This was another inspirational and life changing event for all that attended’, says Paul Steven, TPM Course Instructor. ‘Many of the live improvement projects that were presented to us by the host factory in Shanghai were solved during the two weeks. All teams displayed exceptional skills in World Class Manufacturing techniques; however only one team is selected for best overall outstanding achievement and this time it was the Blue Team, for consistent application of World Class Manufacturing skills.

All delegates who attended the training event will now go back to their individual plants and begin work on their 100 Day plans. This structured implementation of a rigid plan helps to embed the learning that is gained over the 2 weeks, whilst immediately providing payback and a return-on-investment for the respective individual sites.

About KCTS

KCTS are located on the Wirral peninsula and are an international training & consultancy provider of specialist World Class Manufacturing (WCM) standards. Delivering TPM, Lean, Change Management and Policy Deployment programmes to the manufacturing and service industries Worldwide. Through these proven methodologies KCTS can reduce costs by identifying and removing losses within a process or value stream. For further information regarding this press release or KCTS, please contact; KCTS on 0151 608 9036 or visit www.kcts.co.uk

END

Saving Time and Money with WCM

Thursday, April 1st, 2010

How to save a Million Euros 95 times…

207,000 employees, worldwide sales of 42 Billion Euros, manufacturing facilities in 54 countries and a plan! Well a journey to be more precise; a journey that began in the boom time of construction and now starts to shine on a gloomy economic landscape.

In 2002 British Plasterboard (BPB) now Saint Gobain Gyproc, began implementing the ‘plan’. Consisting of an improvement programme that was to make their process plants part of the best performing sites right across industry; and for Saint Gobain, who are the Worlds largest plasterboard manufacturer, looking back at the original vision to increase equipment effectiveness and to up-skill the workforce, this initiative has resulted in a very wise move indeed. For a global company to operate successfully today their business must be ship shape, robust and at the very least have all ‘basic conditions’ taken care of, whilst a focus remains on costs.

That’s a tick in those boxes then. But how does an international organisation move from their current state to the beginning of a continuous improvement journey? Clive Poole, World Class Manufacturing Development Manager for Saint Gobain Gyproc gave me an insight into what he thinks is the key ingredient to the programme. “People. We invest in the development of our people at all levels of the organisation. Our aim is to give everyone simple but effective methods to solve day-to-day problems that are encountered in the workplace.

“We’re developing a culture of empowerment, where employees are encouraged to understand the plant losses, and prioritise activities so that they can take ownership of their work area and run it like it was their own business. Under this new culture, our overall business performance has increased steadily year on year delivering results for our customers and our business, which is a fantastic testament to everyone involved.”

Total Productive Maintenance

Saint Gobain has chosen the methodology of Total Productive Maintenance (TPM), which is in fact the back bone to the highly successful Toyota Production System. The fundamentals to TPM are to ensure that equipment you have invested heavily in is available when you need it. “We choose to use Total Productive Maintenance as a core part of our improvement programme, as at the time, the main issues facing us were machine reliability.  Says Jim Sisson, Saint Gobain Gyproc Engineering & World Class Manufacturing Director.

“We also avoided the ‘Lean’ approach as our machines were not yet reliable enough to allow us to reduce our stocks, and TPM led for a more flexible manufacturing system as there are many aspects, which are referred to as supporting pillars. These pillars not only cover the maintenance aspect of our business but encompass Health & Safety, Environment, People Development, and Quality.

We also realised that we needed to employ external assistance to provide the necessary skills, and expertise to transfer knowledge to our people. Consequently we chose Wirral based specialist consultancy and training provider; Kaizen Consultancy & Training Services as our partner (KCTS), they have a number of training packages and models which fit in well with our WCM Programme”.

A partnership

So, the scale of a worldwide plan of business improvement looks like a daunting path if travelled alone, but with the right assistance, bigger obstacles become achievable goals. Can a company save 95 Million Euros? That’s a tough call! Can they save 1 Million Euros 95 times? Yes they can….through the duplication of successful improvement programmes. So how is a successful improvement programme implemented? Charles Johnston, Managing Director for KCTS sums it up with; “Determination, oh’ and a bloody good consultancy partner!

“We are now into our seventh year of working with Saint Gobain and it’s been a very exciting process to say the least. I have to commend the organisation for the commitment to such a programme. We’re well known to be a strict consultancy partner that will not allow slippage, and as a client you are either 100% on board or not, anything else fails”. And has the programme been a success for KCTS? “Without a doubt; we are very proud of what we have achieved with the Saint Gobain team.

They have many bronze status plants that are on their way to Silver, which is highly respected in the WCM World Class Manufacturing circles. These are phenomenal milestones but it has not been easy by any stretch of the imagination. We have provided practitioner training in all major plant locations around the World resulting in a core resource of change agents and practitioners throughout the Saint Gobain Gyproc organisation”.

So how does KCTS define success for a client? “The main reason an organisation embarks on a programme of this scale is to make change. The biggest change comes by driving out losses and improving overall operational effectiveness (OEE) which we have done, resulting in tremendous efficiency cost savings over the period. To me, that is success”.

The writing was on the wall

Chambéry, France is a major site for Saint Gobain Gyproc, where they produce a number of products in the Gypsum portfolio, including plaster board for the European market. Nigel Green, Manufacturing Consultant at KCTS recalls, “One particular improvement project was for a system component assembly, where the efficiency and quality of output on that one machine relied purely on the amount of adhesive that was applied to the boards. Naturally, because this was such a critical application of the Wall Partition Assembly Process, there was a tendency to lets say “apply liberally” and the site was using an excessive amount of glue to ensure that there was the correct adhesion, but then this had other implications further down the line.

“It was proposed to the site that the best route to take was to implement a problem solving exercise called Major Kaizen. This type of problem solving is extremely structured and incorporates a step approach learning model which enables the client to embed the knowledge gained, and replicate its application in other ‘loss’ areas of the factory. Once the project team had identified the root cause we then communicated our findings throughout the factory, across all shifts”. And has the outcome proved to be sustainable? “Most definitely, and more importantly the savings continue to come just on this one project. Once the knowledge has been transferred to the onsite practitioners then they are more than capable of using the same toolset in other areas of the site”.

This Wall partition production assembly project at Saint Gobain has reported to have saved the site approx 1 Million Euros to date and this is not an isolated success story. “Many improvement projects began life as training workshops, which are then handed over to the newly trained practitioners for completion” Says Jim Sisson. We now have the tools and the mindset to constantly challenge our performance and to continue to move a step further along our continuous improvement path. KCTS have proved to be a very good training provider assisting us in selecting and using the correct methods. Most importantly the training they give is very practical and allows our people to pick up and use the skills on the shop floor in an extremely efficient way”.

Not just a fad

It’s easy to see why an organisation would relish the idea of introducing structured work patterns and methodologies like Total Productive Maintenance, when savings of 1 Million Euros per project are obtainable. It is the rare few organisations that have the confidence in themselves to pursue such a huge change programme on an international scale without this hindsight. “We knew we had made a very bold move and chosen a traditional TPM route for our manufacturing improvements, but it was the right choice, and to date we have made over 95 Million Euros’ in savings says Jim sisson. However it was the commitment to stay on track whilst other fads were pushed to the forefront that proved the unexpected challenge”.

Video Podcasts for Continuous Improvement Professionals

Thursday, March 25th, 2010

As we move towards a creative society with design and user experience at the top of agendas, publishers of information are looking for new ways to capture the ever decreasing attention span of its readers. To coincide with the UK launch of the Apple iPad in early April, here at KCTS we will be launching a brand new weekly video podcast which will target the manufacturing science and technology sectors, providing weekly snippets of education and learning in rich media format.

As a provider of business improvement training and consultancy services, we are an extremely knowledge intensive organisation with many years of experience in helping global businesses to become successful in manufacturing excellence. ‘We have used our video production facilities to enhance our training courses and consultancy activity for the last 5 years, says Matt Treby, Technical Consultant for KCTS. It is through the medium of video that we will leverage our expertise in order to bring together a series of best practice video casts, which will feature various KCTS trainers explaining their experiences in World Class Manufacturing’

With subjects in Lean manufacturing, Total Productive Maintenance, Value Stream Mapping, Workplace Organisation and many more, we are aiming to offer this content online, through our website and also other 3rd party video podcast hosting sites. This service will be a free subscription and is due to be launched on the 8th April 2010. Further information is available at www.kcts.co.uk

World Class Training to be held in Shanghai

Thursday, February 25th, 2010
Written by: Lee Oxton

Project Teams Workshop

Training in Action

We are set to deliver our flag-ship Total Productive Maintenance (TPM) Instructor Course to world leading plasterboard manufacturer, Saint Gobain Gyproc. The two week event will be held in Shanghai, China and will involve thirty two continuous improvement engineers and other senior personnel representing Saint Gobain Gyproc plants from around the World.

Saint Gobain Gyproc is now into their eighth year of a World Class Manufacturing programme which encompasses 68 manufacturing facilities in 54 countries. The Instructor Course is to be held in April 2010 and will be the thirteenth event held to date, all of which have been delivered by ourselves here at KCTS.

The delegates who will attend this training will be put through their paces and if successful will qualify to Instructor standard in TPM, enabling them to go back to their respective plants and implement improvement projects in areas such as; 5S, Problem Solving, Autonomous Maintenance and Professional Maintenance.

As a result of this training outputs have increased by up to 40%, product quality has improved, safety performance is better and costs have been substantially reduced. Saint Gobain Gyproc have made an estimated 95 Million Euro in efficiency cost savings and are well underway to achieving Silver Plant status within their World Class Manufacturing model, throughout the Global Gyproc division.

SMED Changeover Reduction

Tuesday, February 23rd, 2010
Written By Lee Oxton

5 Phases of Changeover Reduction

5 Phases of Changeover Reduction

This week we’re in Denmark where Malcolm Newman will be hosting a 5 day SMED Changeover Reduction course. Our client is a leading global plastics manufacturer who produce a wide range of packaging for food, cosmetics, chemicals and pharmaceuticals.

Our brief is to advise on some of their production methods which include blow molding, thermoforming and injection molding as well as rotational molding, of which the company is the largest manufacturer in the world!

The Changeover Reduction course is one of the middle level Lean training courses that we run as part of our World Class Manufacturing training programmes, designed to build on other Lean/TPM experiences and to provide the skills and knowledge to help our customers reduce their changeover times on site.

The candidates who will be attending the course in Denmark will be Maintenance Managers, Engineering Managers, Plant Engineers and Production Engineers.  They will all get theoretical training and practical experience needed to lead and complete a changeover reduction project of their own.

This course aims to put the candidates on the shop floor with real factory based problems using the tools and techniques they have learned to reduce any losses of time associated with changeover reduction.

We will be helping candidates focus on “Effective Changeovers”, which covers both the reduction of changeover times and the effective vertical startup of the plant after the changeover.

Get Qualified in Lean Manufacturing

Monday, November 30th, 2009

Step over the competition!

The KCTS Lean Manufacturing qualification is an abridged version of training that we have used to catapult major Blue Chip companies, such as Unilever and Saint Gobain into becoming the industry standard in World Class Manufacturing.

Tackle stubborn projects:

The key to our success over other training providers is that we base our workshops around the completion of real live site projects. The result is a demonstrated improvement in your business KPI’s. We achieve this through the application of Lean tools such as;

Problem solving:
Set up reduction (SMED)
Statistical process control
Visual management systems
Value stream mapping
TPM
5S

Lean qualification further information >>

 

 

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