2. Today’s presentation
• Welcome and Introduction to Andy Smith
• Introduction to Rodgers Leask Ltd
• Introduction to the EPA project
• Define phase of the DMAIC methodology
• Measure phase of the DMAIC methodology
• Analyse phase of the DMAIC methodology
• Improve phase of the DMAIC methodology
• Control phase of the DMAIC methodology
• Project Summary
• Our Sectors for you to peruse at your leisure
• Our Clients for you to peruse at your leisure
Andy Smith EPA project presentation 4/16/2019 2
3. Introduction to Rodgers Leask Ltd
• Established over 30 years – founded 1984 in Derby
• Offices in Derby, Birmingham & South West
• Over 60 engineering and technical staff
• £7.5m turnover (2017)
• 80% repeat business
• Longstanding clients
• ISO certification: 9001, 14001, 18001, 27001
• Recently undergone a Management Buy Out
• There is more information about our clients and business at the end of
the presentation
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4. Introduction to Andy Smith
• Andy Smith – General Manager
• Finance Management
• Information Technology
• Human Resources
• Reception and Administration
• Conformance Management
• Fleet Management
• Facilities Management
• Basically if something needs to be done then you will be
able to blame me if it goes wrong!
Andy Smith EPA project presentation 4/16/2019 4
5. Introduction to EPA project
• Agreed project – Improve engineering departmental efficiencies
• Process adopted – DMAIC (Six Sigma methodology)
• D – Define phase of the
• In this phase I needed to identify the customers needs and the process or products to be improved.
• Management team were identified as the key stakeholders
• Processes were reviewed and inconsistencies identified
• SIPOC was used as a visualisation aid for process reviews
• Key performance measures were identified
• In the Define phase of a project it is critical that you seek and gain buy in from all stakeholder otherwise
you run a significant risk of resources not being made available later in the project
• Problem Statement: Structures are not consistently applying all relevant Health & Safety procedures to their
engineering projects and are not storing the significant project documentation into Workspace inline with the
companies Quality manual – ISO9001.
• These practices need to be measurably improved.
Andy Smith EPA project presentation 4/16/2019 5
6. • M – Measure
• In this phase I needed to map out the “as is” process and this was visualised using
process mapping.
• I collected data from existing internal audits to allow us to set a baseline to measure
improvements from.
• I also collected anecdotal data from the Structure's team as to what they saw the
problems were in their department.
• Following a project review we were able to revise our problem statement.
• Revised Problem Statement: Structures are not consistently applying all relevant Health &
Safety procedures to their engineering projects and are not storing the significant project
documentation into Workspace inline with the companies Quality manual – ISO9001.
• A training plan needs to be implemented to ensure consistent use of Workspace and Health
& Safety application to all Structures projects.
Andy Smith EPA project presentation 4/16/2019 6
7. Andy Smith EPA project presentation 4/16/2019 7
A - Analyse
I analysed data from previous audits which suggested poor adherence to
procedures, inconsistence application of Health and Safety protocols and an erratic
use of Workspace
Drawing numbering systems were being ignored and basic document controls
were not in place
It also became apparent that there was an “age” difference in what procedures
were adopted by whom? And also that any training that had previously delivered
was out of date
We identified the critical documentation which needed to be output from the
engineering process with Structures and this was used to generate a secondary
audit
Following the secondary audit is became even clearer that process and policies
were not being adhered to and that we were not following legal guidance on some
Health and Safety practices
8. Andy Smith EPA project presentation 4/16/2019 8
I – Improve:
• Introduce a review of the Designers Risk Assessment documentation.
• Ensure all engineers were trained in the use of the developed template
• Dynamic Risk Assessment training was to be delivered to the whole of
the Structures department
• Specific Safety Media course were identified as critical training
requirements
• Develop “Introduction to Workspace” training
• Deliver “Introduction to Workspace” training to all of the Structures
department
• Implementation of process for storage and naming of project critical
documentation
• Implement a process to measure all new projects for their adherence
to the new standard
• Implement project auditing as part of the Quality management process
9. Andy Smith EPA project presentation 4/16/2019 9
C - Control
• A Safety Media Dashboard was created to Monitor the uptake of
identified critical training.
• All training was recorded in the Training Matrix
• All Safety Media training is now a deliverable objective in everyone's
appraisal
• The Designer Risk Assessment template is now stored in Workspace (as
a template)
• Monthly project audits are in place with a weighted scoring system
• Engineers now have an improvement objective as an appraisal
deliverable
• All this is now reviewed at the Management meetings as well as the
Conformance meetings
• Identifies failures or potential improvements are fed back into the
regular departmental improvement meetings
10. Project Summary
• Rodgers Leask Ltd identified that they wanted to make a significant
business change to the way the engineering departments operated and
for this to have a Quality and Financial benefit to the business
• Andy Smith undertook a project to identify and deliver this change, this
project became his apprenticeship project which has been presented as
part of the EPA process today
• The engineering departments have already changed their processes and
identified best practice is being shared across departments
• Health and Safety have been significantly improved, the risk of future
claims have been significantly mitigated, Workspace is now a tool we can
be proud of and we are in a better position to enter into negotiations to
reduce our PI insurance even further
• The goals of the project have more than been delivered and
expectations for my next project have been raised significantly.
Andy Smith EPA project presentation 4/16/2019 10
11. Our sectors
Industrial
Manufacturing
facilities – from
automotive to food
and drink
Leisure & Hotels
New build
refurbishment and
extension
Commercial
Retail parks, offices,
town centres, hotels
and multi-storey car
parks
Residential
Low rise, multi-storey
apartments and
student
accommodation
Education
Universities,
colleges
and schools
Healthcare
Medical units,
health centres and
care homes
Nuclear
New build,
decommissioning
and defence
Town Centre
Development
Masterplanning
Distribution
High bay
warehouses and
marshalling
4/16/2019 Andy Smith EPA project presentation 11
Hi everyone, this is the agenda for today’s presentation.
The presentation should only take 15 mins so if you could please save any questions until the end it would be appreciated.
Rodgers Least Ltd is an Engineering Consultancy that has a proud history and uses a “three r” policy at the basis of it’s business:
Reputation
Repeat business
Recommendations
We do have a website and an online presence but we do not actively “advertise” our services.
At this point I would like to thank Rodgers Leask for funding this course and giving me the time to train.
Hi my name is Andy Smith and I am General Manager of Rodgers Leask Ltd.
I would like to welcome you to this now 13 min presentation on my EPA project, again I would appreciate it if you could save any questions until the end.
I am responsible for the “non engineering” functions within our business and I always say that “if you need someone to blame then it will usually end up with me”.
I have worked here for just over 3 ½ years and I have spent most of that time introducing “change” to Rodgers Leask Ltd, including the introduction of CTskills apprenticeships.
Why DMAIC?
I have been involved in many change projects over the last 30 years and have adopted a process that I feel best supports my customers but that I also feel I can utilise without confusing them with any “management jargon”.
I use the Six Sigma methodology called DMAIC which I will take you through over the next few slides.
I did not tell the project team that I was following this methodology but I did ask them to give me their input and I applied the methodology in the back ground. Over the years I have found that talking “jargon” to people really switches them off.
So step one of the methodology is Define: We used the Define phase to get an agreed Problem Statement for the project.
The identified problem statement will have an impact on project Quality, speed of access to project data and introduces an opportunity to further reduce the companies Public Indemnity Insurance; Quality improvements over the last 2 years have already been a key factor in reducing our PI insurance by over £80k.
Measure: The key part to the Measure phase of a project is to collect data and the “as is” state within the business.
I have used a SIPOC for many years now to help visualise the inputs and outputs from a process, these tend to lead you in the right direction and to what needs to be measured. In our project meetings we visualised the process and confirmed that there were no “project” audits in existence.
It is important to collect as much data as possible during the measure phase of a project, but always remember that if you collect data you will need to analyse that data at some point during the project cycle.
We also carried out an FMEA to see what factors would prevent us from being successful, these were minimal as the MD had given his authority to improve whatever wee felt necessary, any escalation was to be through him directly.
Analyse: The key purpose of the analyse phase of a project is not review all data collected during the project, including process maps and procedures.
The analysis phase provided quite damning information to suggest that things were actually worse than originally thought. It became apparent that basic Health and Safety was not understood and that basic legal requirements were being omitted.
Improve: The improve phase is used to identify what changes we are going to implement during this project.
This was our plan:
Introduce a review of the Designers Risk Assessment documentation.
Ensure all engineers were trained in the use of the developed template
Dynamic Risk Assessment training was to be delivered to the whole of the Structures department
Specific Safety Media course were identified as critical training requirements
Develop “Introduction to Workspace” training
Deliver “Introduction to Workspace” training to all of the Structures department
Implementation of process for storage and naming of project critical documentation
Implement a process to measure all new projects for their adherence to the new standard
Control: The Control phase is used to identify how you are going to monitor the improvements that were implemented during this project.
A Safety Media Dashboard was created to Monitor the uptake of identified critical training.
All training was recorded in the Training Matrix
All Safety Media training is now a deliverable objective in everyone's appraisal
The Designer Risk Assessment template is now stored in Workspace (as a template)
Monthly project audits are in place with a weighted scoring system
Engineers now have an improvement objective as an appraisal deliverable
All this is now reviewed at the Management meetings as well as the Conformance meetings
Identifies failures or potential improvements are fed back into the regular departmental improvement meetings
Read the summary as is.
Thank you all for taking the time to listen to me today and I hope you found the presentation informative.
That is the end of todays presentation so its thank you and goodbye from me.
