Building Responsibility and Accountability for Quality and Delivery with Lean Manufacturing

Challenge
This long-established metal processing company was faced with problems common to many heavy industrial manufacturers, namely strong unionisation, increasing pressure from imports and product substitution, limited product differentiation, rising operating costs and declining volumes. The company’s challenge was to achieve simultaneous improvements in SQDCP (Safety, Quality, Delivery, Cost, People) and to differentiate itself to customers through quality and delivery. Corporate Partners was brought in to help meet the challenge.

Excellent Outcomes at a Glance

  • Quality: Reduction in rejects of 65%
  • Delivery: Improvement in DIFOT from 75% to 98%
  • Delivery: Reduction in lead-time from 12 to 6 days
  • Safety: Reduction in referable injury (TRIFR) from 45 to 28 (Improvements continue, the current TRIFR is 10.9)
Solution
Corporate Partners set about understanding all the elements of the manufacturing process from actioning an order to making final delivery. They identified a high percentage of rejects as an issue, and worked on instilling a philosophy to never accept, never make, and never pass on poor quality. This required a paradigm shift from relying on the final inspection to building quality into every stage of the manufacturing process.

Mini Business Teams (MBTs) played a vital role in bringing about this shift. MBTs were established and customer-supplier relationships were set up between MBTs for all internal processes. The MBTs were empowered to set expectations for quality and time of delivery, and to identify and address the root causes for failing to meet these expectations.

DIFOT (delivery in full on time) was formally measured and recorded, and as a consequence all MBTs became more focused on solving the problems of material and information flow.

Another focus for the company was improving safety. Corporate Partners applied the 5S tool as well as visual safety discussions (among MBTs) to create a safe, organised, productive and clean workplace.

DIFOT performance for metal processing company

DIFOT was formally measured and recorded and became a focus for all teams.