SJW Associates (UK) Ltd. - Operational Improvement Strategies

Operational Improvement Strategies

SJW Associates (UK) Ltd.

Hands-on lean operational advice to improve quality, cost and delivery.

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Case Study: Quality Improvement & Waste Reduction

Terms of reference

A SME manufacturing plastic sacks required assistance to raise its product quality and reduce its wastage costs to improve service to customers and to strengthen bottom line performance.

Project objectives

The overall project aims were:

To assess the plant’s true levels of quality and waste

To determine the root causes of the quality and wastage problems

To determine a programme to improve these key measures

To facilitate and train the staff to deliver the improved performance

Process of delivery

The project was delivered in the following phases:

A detailed Lean Operational Assessment established the underlying levels of performance and improvement targets to provide a business case for improvement

Systems for accurately measuring all quality and wastage issues and their cause were developed and installed

A regular improvement meeting was developed for the business and facilitated to ensure that root causes were identified and corrective actions put in place

Systems were developed for communicating and training operational personnel to ensure that problems were identified and corrected during manufacture and not at the customer

Project outcomes

The project achieved the following:

The cost of quality has been reduced by a factor of 10

The level of production waste has reduced by 40%

All raw material issued to the factory can now be reconciled with finished product sold

Bottom line performance has been significantly strengthened

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