continuous improvement RICHARD HUGHES MICHAEL MCLEAN FAICD, CMC - - PowerPoint PPT Presentation

RPC Technologies Pty Ltd

The potential offered through continuous improvement

Presenters:

RICHARD HUGHES

WHSQ Manager RPC Technologies

MICHAEL MCLEAN FAICD, CMC

Managing Director McLean Management Consultants

27 November 2013 Sydney Convention Centre Darling Harbour

WHO WE ARE. RPC is a global leader in design, engineering and manufacturing of fibre composites and advanced materials

Composite materials are re-shaping our world, and RPC is reshaping the way advanced composites are blended with more traditional methods of production to deliver engineered and manufactured solutions that take performance to the next level.

RPC Technologies Pty Ltd

Transport

RPC Transport designs and manufactures an extensive range of interior and exterior components for the public transport sector.

RPC TRANSPORT

Don’t be fooled in to thinking you can replicate the “Toyota Way”

 Within RPC we realised we have a totally different culture and we can never expect to be another Toyota…..but we can learn from them.  We looked within our own organisation to determine our own strengths and used those to our advantage The assistance we received through Enterprise Connect and our consultant during this process proved invaluable.

RPC TRANSPORT What is the purpose of LEAN?

To eliminate waste (8 wastes).

RPC TRANSPORT What was our LEAN leadership strategy?

1. A Lean Vision was defined. 2. A road map and key milestones was developed. 3. Appropriate milestones were set to monitor progress. 4. Resources were identified and available. 5. Working groups were formed (Teams) 6. Ownership of key processes was defined. 7. Metrics were established to measure performance. 8. Individuals were made accountable to the team. 9. The team is accountable to our Leadership.

• 10. The Leadership is accountable to everyone.

RPC Transport offers the best of both worlds when it comes to internationally cost competitive supply chain solutions, backed by Australian engineering, client understanding and transport know how.

RPC TRANSPORT LEAN Principles

Lean manufacturing is underpinned by 5 principles:

• 1. Specify what creates value from the customers

perspective (what they want, when they want it at the

price they are willing to pay).

• 2. Identify all the steps along the process chain

(process mapping - reduction in waiting, downtime, and waste).

• 3. Make those processes flow (improve processes)
• 4. Make only what is pulled by the customer (do not
• verproduce. Make only what the customer requires –

reduction in inventory)

• 5. Strive for perfection by continually removing wastes

(pursuit of perfection – zero defects).

RPC TRANSPORT Steps to LEAN (Our roadmap)

• 1. AWARENESS - At all levels of organisation
• 2. 5S - Organise the workplace
• 3. VALUE STREAM MAPPING INFORMATION and

MATERIAL FLOW TASKS*

• 4. FLOW MANUFACTURING Improve plant layout
• 5. LEVEL PRODUCTION Reduction of:
• lot sizes
• setup times
• lead times
• inventory
• 6. STANDARDISE OPERATIONS TO SUPPORT 8D

PROBLEM SOLVING* AND

• Improve quality and

maintenance

• Simplify processes

In support, RPC Transport provides solutions in relation to front ends, wall vestibules, ceiling skirts, modesty panels and toilet modules, refurbishment of railcar seating, lighting systems, ballistic and non ballistic masks, nose cones and coupler fairings. * Womack, Jones & Roos “Lean Manufacturing” 1997 page 19 “Value Stream 3 Critical Tasks”

Transport

RPC TRANSPORT What next for RPC Technologies?

1. EC SCIP II to support our Back-end management and support process:

• Procurement
• Project Management
• Engineering and
• 2. AS9100-C implementation and certification

RPC SCIP I summary of TAS MMC assistance :

• 1. Understand client management systems,

strategies, processes in their context

• 2. Build steering committee, report progress to EC

template, define projects and teams

• 3. Contextualise 4 x AQF CS&P Cert IV modules and

use Adult Learning to apply Core Tools to Projects

• 4. Space team training to enable data collection
• 5. Complete Team & Personal coaching Tasks

MMC Pty Ltd is an Enterprise Connect ‘Tailored Advisory Services’ management consultancy

www.mclean-mc.com.au

• 1. Determine RPC process stability, ‘MUDA’ in process

and capability to deliver

• 2. Define the “S>I>Process>O>C” flows
• 3. Understand internal / external Supplier inputs, quality,

risks, constraints and dependencies

• 4. Agree what to “Keep-Change-Create” a safe work

environment and remove ‘MUDA’ < ‘3S’

• 5. Select ISO9001 QMS Process & Procedures that

each team will review and improve

• 6. Use Kanban and ‘Right 1st Time’ in all processes

Achieving Customer [Downer EDI] ‘TAKT’ or ‘Beat’ Time targets by……

www.mclean-mc.com.au

Enterprise Connect SCIP I & II Core “20 Tools” with 8D Problem Solving / ISO9001/4 QMS

www.mclean-mc.com.au

Enterprise Connect SCIP I Reporting Templates with TAS AQF CS&P IV Cert Projects and Visual Management reporting templates

www.mclean-mc.com.au

John Krafcik, now Hyundai USA Strategic Planning VP and ex MIT International Motor Vehicle study and Researcher with Prof J P MacDuffie and “Lean” originator (1987) said: “design accounts for about a third of the productivity and quality that can be achieved.

http://www.just-auto.com/analysis/john-krafcik_id86302.aspx

www.mclean-mc.com.au Who’s responsible productivity and quality?

www.mclean-mc.com.au

Dr Juran’s Pareto and Dr Deming – Management is >80% responsible for productivity and quality?

Enterprise Connect – Sustainable Continuous Improvement Program I 2012/13

http://www.enterpriseconnect.gov.au/media/Pages/ClientJourneys/Manufacturing/RPC-Technologies.aspx

www.mclean-mc.com.au