1. A CONTINUING JOURNEY TO EXCELLENCE
Our Lean Journey
A CONTINUING JOURNEY TO EXCELLENCE

2. Agenda Our original Goals How our Journey Began
What we looked like before
The Idea
What we look like now
Tools we introduced
Our search for waste
What are we doing going forward
Results

3. Our Original Goals To improve quality To improve productivity
To improve profit
To attract more custom

4. How Our Journey Began
Looked at our factory and knew things had to change
VIP help us with our first 5C exercise
Had to rejig the factory layout
Planning, Planning and More Planning

9. The Way We Were

10. The Idea

11. The Way We Are

14. Tools We Introduced 5c
OEE
TPM
Product Flow

15. 5c Began with training in all areas Introduced 5C Walks
Monthly 5C Audit
All very successful

16. 5C Audits

17. OEE Next we had to look at how we perform
Again VIP helped us with our first workshops
Been a slow process
Time sheets
Soon to be automated
Using the data have reduced portering

19. TPM
Each machine on the shop floor has a TPM book to record the daily, weekly, monthly tasks
On a monthly basis we record how effectively the operators have been in Performing the TPM Tasks
Through OEE we track maintenance downtime and determine areas of concern and proposed actions

21. Used Value Stream Mapping
Mini Warehouse (Job Assembly)
Bench
Planning
Postage
Projects
Remake Area

23. Our search for waste Put up the following poster
Got reaction, not necessarily what we wanted
Bill and I Had some explaining to do
Our wanted poster is still up as Tim is a very illusive character

25. Results
More clients
Increase in volume-more packs mailed out than ever
Profitable
Increased opportunities for investment
A site that we can be proud of

26. Going forward Implementing Net Consent
Introducing two hour work shops as a refresher
Continue refining our factory layout
More Value Stream Mapping Exercises
The recording of OEE and TPM data will be automated

27. Closing Thought
What we have found with all of the Lean tools that have been implemented in Dagenham is that none of them will get off the ground without their ownership being firmly in the hands of the recipient. BUY IN is the key ingredient to any successful implementation