On October 23rd, 2014, we updated our
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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
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
The Doom Cycle Rob production line of resource, to repair => Further delay, more defects from line…. vicious cycle. PASS
Design change Lack of operational, robust quality systems Detailed process planning
Cost associated with:
Inadequate / poor production preparation Defect repair
Fundamental Concerns Skills base has been lost in the period of inactive manufacture Shortage of knowledge Shortage of experience
Status of essential needs Dormant period- almost 20 Yrs Experienced Engineers Experienced Hard Skills: Artisans Skilled Workforce Supplier base
Status of essential needs
One Generation is LOST in essential skills of Rail Manufacturing.
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
“My Problem” activity (People involvement)
Focussed rescue intervention: UCW, TOSHIBA Inspectors Skill Electric Skill Piping Skill Weld School
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
Defect feedback & root cause analysis & eliminate
Detailed work instructions, quality key points defined
Trained people working as teams
Detailed Task List and progress tracking
Detailed parts management
Capable Shop Floor Leaders
ARE WE READY ?
Have to ENSURE we retain Skill & Experience
Core skills development Before we start manufacture
LIMIT the amount of change at project start
Sustainability of business is directly linked to the stability of demand.
ARE WE READY ? Yes and No…….
We have pockets of excellence available in SA manufacturing industry
Require people training and development; investment by industry who hope to participate, without certainty of actually doing so
It is too late to start development & training, after the contract is awarded
There is much to do………
We will succeed! We are South African! We have expert support available