Delivering a step change in operational performance

The issue

Four factories on one site producing 60% of the company’s European demand for the Automotive market
Utilisation and performance had been in steady decline for four years and with very poor customer delivery and service performance this was seen to be a failing site
Local custom and practice was inhibiting opportunities to improve productivity
Curzon was engaged to help the Site Director achieve control and turn performance around
The site was achieving less than 60% OEE on its premium integrated lines
High inventories but of the wrong products due to lack of control of demand and production priorities
No performance management system in place to drive improvement
Disconnected Planning and Production functions causing late delivery and high costs
Limited management capability and lack of proactive supervision

What we did

Create an overall approach to transform the performance of the site involving all of the management team
Implement a cross-functional planning process and tools e.g. production wheels to establish a clear view of demand, delivery priorities and factory capability to deliver
Implement Lean capabilities on the shop floor e.g. SMED techniques, SIC and Kaizen to improve productivity and develop a sense of ownership
Selective capital investment in facilities (underway)
Implement visual performance management and supporting proactive supervisory/management processes
Build the capability of the local team to ensure sustainability

The results

Achieved in excess of 25% reduction in inventories and a significant uplift in on time delivery to distribution centres
Improved OEE on key integrated lines by over 20%, increasing capacity and enabling transfer of work from less productive sites
Built the capability of the client team to be able to complete the programme rollout successfully themselves and to sustain the initial improvements
Created a blueprint that can be rolled-out to other sites globally

25M

reduction in inventories

20%

increasing capacity

What we have achieved with our clients

Award-Winning Procurement Transformation Programme

Driving market focused resource allocation decisions

Providing a clear route to meet sustainability objectives for a major UK Airport

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What our clients say

“As a result of Curzon’s support a strategic and digital leap has been made in how we manage the entire asset lifecycle to transform our Developer Service experience. This is a programme and a product that sets a new benchmark within the industry.”