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Similar to Talking Business Conference Our Journey to Excellence (20)
Talking Business Conference Our Journey to Excellence
- 3. Introduction
The Hi-Technology Group Ltd. is privately owned injection moulding facility, providing total concept
manufacturing to the medical, marine, H&S, defence, mobility, aerospace and consumer industries
Hi-Tech Mouldings based in Hi-Technology mouldings Slovakia sro based
Waterlooville, Hampshire, UK in Kosice, Slovakia
3 shift patterns – 134 employees 3 shift patterns – 26 employees
A trained workforce with developed skills and dexterity meet the challenging needs
of the business, implementing 5S techniques and OEE
© The Hi-Technology Group LTD 2012
- 4. Services
• Product Design
• Tool making
• Injection Moulding
• Product Assembly
© The Hi-Technology Group LTD 2012
- 5. Performance
Group Performance
12,000,000
10,000,000
Turnover (£)
8,000,000
6,000,000
4,000,000
2,000,000
0
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
(projected)
Year
© The Hi-Technology Group LTD 2012
- 6. The Journey
?
2005
© The Hi-Technology Group LTD 2012
- 7. The Issues
Low Investment
Poor Training
Flawed management
Major customer Offshoring
© The Hi-Technology Group LTD 2012
- 8. Where did we go from here?
“What we need to do
“What improve our is improve?”
work methodology?”
“What we need to do
is find out where we
We’ve tried that and it didn’t work! are?”
We know what to do but we’re just too busy to do it!
We will make a start once things improve!
What make improvements when we just can’t sustain them!
It’s just another initiative, will soon move on to something else!
© The Hi-Technology Group LTD 2012
- 9. Leadership
Leadership is about
creating the conditions
for others to succeed
© The Hi-Technology Group LTD 2012
- 10. The 3 P’s
People
Polymer
Process
© The Hi-Technology Group LTD 2012
- 11. The challenge
You have to challenge the
accepted norms at grass root
level; aspects such as
changeover times, inventory
requirements, absenteeism.
However, you need to get
away from personalities and
build good
optimised, documented
processes and procedures
© The Hi-Technology Group LTD 2012
- 12. Why Benchmark
The main reason to benchmark is because you
recognise that somewhere, somehow you are not as
efficient or as capable of satisfying your customers as
your competition
There are two key drivers - profitability and revenue
growth
Although benchmarking is a measurement process and
does generate comparative performance measures, it
also about attaining exceptional performance
© The Hi-Technology Group LTD 2012
- 13. Why Benchmark
Processes, although a temporary component of an
organisation because they change easily, are critical for
profitability as delivery of products/services is crucial to
customer satisfaction, payments and ultimately profit.
Similarly reputation (ephemeral) is critical to growth
but can be lost all too easily - especially if
processes/people do not deliver
(A . Anderson)
SUSTAINABILITY IS THE KEY
© The Hi-Technology Group LTD 2012
- 14. Why Benchmark
Temporary
Reputation Brand
Culture
Investment Capital
People Processes
Growth Financial
Profit
Structure Operation
Equity
Control
Software
Products Procedures
Hardware
Assets
Durable
© The Hi-Technology Group LTD 2012
- 15. Initial Benchmark Result
Customer Satisfaction - above average
Safety Environment Cleanliness – average
Management Deployment – below average
Scheduling – average
Product Flow, Space use – below average
Inventory WIP levels – below average
People teamwork, skill level – below average
Equipment and tooling maintenance – below average
Ability to manage complexity – average
Supply Chain Integration – average
Quality System Deployment - average
© The Hi-Technology Group LTD 2012
- 16. Our practices had become our working habits
They would be hard to change. People were not necessarily against
change but they were resistant to being changed
Changing our practices was more of a cultural challenge than a
technical one
•Tools, techniques and knowledge of alternative practices would
help but would not be enough on their own
•We required our people to be empowered to change their own
practices supported from the top
•Leadership is a key competency and this needed to be developed
•New habits would take time to establish and need coaching
© The Hi-Technology Group LTD 2012
- 17. We had to recognise we needed to -
• Embrace new technology and R&D when applicable
• Support the develop of new products quicker
• Help bring products to the market place earlier
• Adopt where feasible technology transfer between
sectors
• Diversify into other products/sectors
• Improve productivity & competitiveness
• Drive down manufacturing costs
But you have to give people the right working environment
to succeed.
© The Hi-Technology Group LTD 2012
- 18. Eight Principles
1.Customer Focus
2.Leadership
3.Involvement of People
4.Process Approach
5.System Approach to Management
6.Continual Improvement
7.Factual Approach to Decision Making
8.Mutually Beneficial Supplier Relationship
© The Hi-Technology Group LTD 2012
- 19. Business Framework
Provides the route to success • Improve understanding
• Identify the way we work
Creates ownership • Recognise and improve
the systems we use
Instils Pride • Identify the support and
training required
Leads to Success • Formalise the
recognition employees
get
Peoples capability +
Management motivation
© The Hi-Technology Group LTD 2012
- 20. Current Benchmark Result
Customer Satisfaction – Excellent
Safety Environment Cleanliness – Excellent
Management Deployment – Excellent
Scheduling – Excellent
Product Flow, Space use – Excellent
Inventory WIP levels – Excellent
People teamwork, skill level – Excellent
Equipment and tooling maintenance – Excellent
Ability to manage complexity – Best in Class
Supply Chain Integration – Excellent
Quality System Deployment - Excellent
© The Hi-Technology Group LTD 2012
- 21. Individuality and Vision
Attributes – What are the distinctive Consistently
Innovative Flexible
attributes of our business? High Standard
Exceptional Collaborative
Functions – What do these bring to our Product
quality (product approach with
business? Specialism
and Service) customers
Secure,
Confident of our Valued and
How does this make our customers feel? confident of our
ability respected
performance
Builds
Differentiation
Values – What core values does this give our High trust in our relationships
from our
business? ability and long-term
competitors
partnerships
Personality – What type of “personality” does Preferred Long
Unique High Integrity
this give our business? term partner
Leader in design and manufacture of polymer solutions
Vision
for our customers
© The Hi-Technology Group LTD 2012
- 22. Vision and Strategy
Targets
•Balanced market Portfolio
•Robust succession planning
•Long term tool manufacturing plan
•Lean manufacturing and automation
•Lean procurement and logistics planning
•Profitable business growth VISION
12 million turnover
© The Hi-Technology Group LTD 2012
- 23. Vision and Strategy
How do we achieve this?
• Sales
• Development
• Manufacturing
• Procurement/Logistics
• Quality
2012-13
• Slovakia
Hi-Technology
Group £12 m
t/o
© The Hi-Technology Group LTD 2012
- 24. Direction
• Leadership and team building set
the foundations for business
improvement and success
• Strong focus on continuous
improvement and integrated
management has improved
manufacturing planning and
boosted productivity.
© The Hi-Technology Group LTD 2012
- 25. Main points
• Clear Deployment of Strategy and
resources
• Skilled, self starting high performance
team with a strong sense of a shared
purpose
• Working with OEM customers in design
Development to bring product to market
via simulation and RP techniques
• A Culture of improvement and involvement
underpinned by training, lean activity and
capital investment
© The Hi-Technology Group LTD 2012
- 26. IT at the Centre
SALES
WAREHOUSE PLANNING
DISPATCH LOGISTICS
PRODUCTION
© The Hi-Technology Group LTD 2012
- 27. What have we learnt?
• Define/Measure/Analyse/improve/Control
• The 6S’s Principles – Sort, Set in
order, Shine, Standardise, Sustain, Safety
• Value stream mapping
• Supplier OTIF/ PPM
• Customer OTIF/ Forecasting v Actuals
• OEE (Overall Equipment Efficiency/SMED
(Single-Minute Exchange of Die)
• New Product Introduction (Make order
process)
• Design of Experiments/SPC
People are our major asset and we should
train & empower them to succeed
© The Hi-Technology Group LTD 2012
- 28. Training
Training may be perceived as unglamorous and
usually the first item to be cut from the budget
in difficult times but it is crucial to the future
success of a business
If you fail to train you are planning to fail
© The Hi-Technology Group LTD 2012
- 29. Training planned 2011
Training 2012
• AAT Level 4 Diploma
• Negotiation Skills and Structured Selling Course
• Essential Selling Skills
• Key Account Management
• MAS Lean Manufacturing
• MAS Value Stream Mapping
• 3 Apprentices – Technician, Tool Making, Business Administration
• 2 Undergraduates on placement
• Key Skills training
• Supervisory Training
• Fundamentals of injection moulding training
• High Performance Moulding
© The Hi-Technology Group LTD 2012
- 30. Main points
• A business wide passion for customer service and
focus on OTIF achieved better than 99%
• Niche market needs are identified and met
through a partnership approach of innovation
with the customer
• Focused to meet customers expectations
• Shop floor led improvement via NVQ training
initiatives
© The Hi-Technology Group LTD 2012
- 32. Summary
• Sustained growth of 18% and 10% last two financial
years and 10% planned for 2012-13
• Continued investment in staff training (1327 days
of training undertaken, this equates to 9.83 days
average per employee.)
• Annual Absenteeism down to 0.25%
• Supporting Apprenticeship and Undergraduate
training. Recognised as a Cogent Gold standard
training provider
• Working with Major OEM across multi-sites to
deliver Polymer Training and product development
• Continued investment in plant and equipment to
remain competitive and provide sustained
employment in the area.
© The Hi-Technology Group LTD 2012
- 33. Summary
Processes are evolutionary and will continue
to change and adapt, we need to be planning
and preparing ourselves for this.
We want to be a centre of
excellence, exploiting new opportunities, new
technologies enhancing learning and raising
our standards
© The Hi-Technology Group LTD 2012
- 34. Success – Our Awards
Exporter of the Year
Finalist 2008
2011 – Winner –
Growth Business of 2012 Finalist
the Year
© The Hi-Technology Group LTD 2012
- 35. Awards 2012
SME Manufacturer of the Year Finalist
ICT in Manufacturing Finalist
© The Hi-Technology Group LTD 2012
- 36. The Journey
200?
2012
2011
2010
2009
2008
2007
2006
2005
© The Hi-Technology Group LTD 2012