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UCW - UNIDO SPX rhythm 25082011
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UCW - UNIDO SPX rhythm 25082011 Presentation Transcript

  • 1. Preparing South African Manufacturers for Major Projects
  • 2.
  • 3. Misconception of Status
    The South African nature:
    Optimistic
    Superficial in dealing with detail
    Over-Estimate
    Own Ability
    State of Readiness
    We are “World Leaders” in Crisis Management
    Over-promise and under-deliver
  • 4. We always think of delivery…….We promise improvement, and then focus on getting units to the door, and ?....…..
    Reality shows that Quality prevents / disrupts delivery with =>
    Serious impact on the customer’s experience and cost
    Threatening the company’s own financial security
    Under-performance & reputation damage
    Situation
  • 5. The Doom Cycle
    Rob production line of resource, to repair =>
    Further delay, more defects from line…. vicious cycle.
    PASS
  • 6. Situation
    Underestimate….
    • Impact of:
    Design change
    Lack of operational, robust quality systems
    Detailed process planning
    • Cost associated with:
    Inadequate / poor production preparation
    Defect repair
    • How quickly CASH problems cripple the company
    • 7. Training in advance
  • Case: Project Delivery
    12 month delay
    18 month delay
  • 8. Fundamental Concerns
    Skills base has been lost in the period of inactive manufacture
    Shortage of knowledge
    Shortage of experience
  • 9. Status of essential needs
    Dormant period-
    almost 20 Yrs
    Experienced Engineers
    Experienced Hard Skills:
    Artisans
    Skilled Workforce
    Supplier base
  • 10. Status of essential needs
    • One Generation is LOST in essential skills of Rail Manufacturing.
    • 11. The young have just started
    and are inexperienced.
    • Critical mass of skilled and experienced people for major projects, have not yet been developed.
  • Case: Project Delivery
    INTERVENTIONS
    • Training
    • 12. Production Control
    • 13. Quality Gates
    • 14. “My Problem” activity (People involvement)
    Focussed rescue intervention:
    UCW, TOSHIBA
    Inspectors Skill
    Electric Skill
    Piping Skill
    Weld School
  • 15. Corrective Action
    Massive effort to save projects by:
    Mitsui (MARS, VENUS)
    UCW
    TOSHIBA (Japan Expert Support)
    Cost impact on customer and contractor due to delay
    Cost impact of developing essential needs DURING contract delivery period
    NOW
    FUNDEMENTAL SKILL JUST AGAIN DEVELOPED
  • 16. Imperatives
    • QC Network
    • 17. Defect feedback & root cause analysis & eliminate
    • 18. Detailed work instructions, quality key points defined
    • 19. Trained people working as teams
  • Imperatives
    • Detailed Task List and progress tracking
    • 20. Detailed parts management
    • 21. Capable Shop Floor Leaders
  • ARE WE READY ?
    • Have to ENSURE we retain Skill & Experience
    • 22. Pre-production preparation
    • 23. Project Management
    • 24. Core skills development Before we start manufacture
    • 25. LIMIT the amount of change at project start
    Sustainability of business is directly linked to the stability of demand.
  • 26. ARE WE READY ?
    Yes and No…….
    • We have pockets of excellence available in SA manufacturing industry
    • 27. Require people training and development; investment by industry who hope to participate, without certainty of actually doing so
    • 28. It is too late to start development & training, after the contract is awarded
    • 29. There is much to do………
    We will succeed!
    We are South African!
    We have expert support available
  • 30. THANK YOU