Global companies and how they become successful

1. The Top Ten Secrets of the World's Most
Efficient Manufacturers
Presented by
Keith Findlay

2. Part of Consulting
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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#1
Have 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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#2
Believe 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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#3
Have realism about what will be
accomplished but energise your
team for more
Your 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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#4
Be 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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#5
When it doesn’t go to plan
(and it won’t!)
commit to problem solving as a
way to recover
This will empower your people to be accountable and responsible for the
outcome, both good and bad

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#6
Celebrate your successes when
they happen
At 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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#7
Commit to the Standard
– start as you mean to go on
If 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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#8
Visually promote the message –
advertise your intentions
Never 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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#9
Know that this will need financial
investment of some kind
Endeavour to release the funds to complete tasks in a timely manner.
Momentum is everything

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#10
Be 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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Statistics Even 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.