Comfortex
Comfort Seating Products
Comfort Seating Products
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To provide training/support to core staff in tools and techniques to enable them to undertake a line leadership role as part of a restructuring of the business.
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Project Description:
Managing Director, Nathan Beckwith, wanted to restructure the management configuration within the business to drive the business forward at a greater pace. He had taken the step of dividing the factory into work-zones, identifying several people as potential Leaders for these work-zones. Immediately, he recognised that the group required some support and upskilling in order to take on these roles. IW Process Solutions developed a bespoke training course for the group covering a range of subjects combining lean manufacturing techniques with the interpersonal skills necessary to be an effective leader. Following the delivery of the training programme, a number of Consultancy days were planned to support the group on a one-to-one basis in their areas to ensure that they were fully applying the learning. IW Process Solutions generated a series of observation reports from these areas with potential Productivity improvements which could be achieved. As a result of an observation report in one area, it was decided to use the area as a Practical workshop for the group to apply the knowledge learned on the course to initiate the changes identified in the report. This resulted in a 25% Productivity improvements from the application of single piece flow in the Seatpads area, through changes made to the layout and working methods employed in the area. Other elements from the course were also incorporated, such as a performance monitoring system so that output could be monitored hourly to ensure the takt time was being adhered to. Additionally, a structured workplace management system was set up which defined hourly tasks for the Zone Leader to ensure that all aspects of the operation were where they needed to be, including pre-planning activities for the following day’s production. To finish off, workplace organisation was implemented to create a more organised and tidy work area. Finally, to support ongoing improvements, Nathan asked IW Process Solutions to work with a group of the middle management team with the aim of training them to see the potential improvements for themselves. Using the Observation reports as a script, the group spent time analysing individual areas under IWPS guidance so that they developed their own improvement plan for each area which they then actioned to make the changes and bring about the Productivity improvements. |
This picture depicts the reason for the restructure of the management configuration within the business and was an underpinning influence on the training course content.
This picture shows the groups working out how the process cycle times in Seatpads measured up against the takt time they’d calculated. From this, the group determined how many people would be needed and who would be doing what to balance the work content as equally amongst the team as possible.
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This picture shows the groups revised layout for the Seatpads process to accommodate the new working methods.
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This picture shows the groups draft format for the Short Interval Control (SIC) board for the Seatpads area.
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