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Operational Excellence in Manufacturing - delivering year-on-year performance improvement
A programme developed by Conference Communication and DAK Consulting
25 November, 2008, at Scarman House Conference Centre, University of Warwick
Click here to register
Who should attend?
Functional heads, improvement programme sponsors, change agents and individuals who want to develop their understanding of the practical realities of delivering sustained year on year operational improvement.
Programme Outline
Delivering consistent year on year improvement in performance takes more than a single idea, improvement project or killer improvement tool. This level of organisational capability is only achieved when management is able to engage all levels in the organisation behind a focussed but constantly evolving improvement agenda.
The evolutionary nature of the task is due to the way that the improvement process develops individual and team capability and confidence to act. To harness this energy, there is a need to systematically redefine roles, accountabilities and working relationships to create the 'headroom' to develop at all levels.
Timetable for the day
08.30 Registration and coffee
09.00 Introduction. Session 1: SETTING THE IMPROVEMENT AGENDA
09.15 CASE STUDY Bill Riseborough, Reliability Champion, Dow Corning
10.00 Workshop Session - Winning hearts and minds
10.30 Break
10.50 Session2: TAMING TECHNOLOGY LEAN MAINTENANCE Paul Wheelhouse, Principal Consultant, ESS Ltd
11.35 Workshop Session - breaking down barriers between functions
12.00 Panel Session - Delivering stable operations
12.30 Lunch
13.45 Session 3: HOLDING THE GAINS. CASE STUDY. Derek Cochrane, Engineering Specialist, 3M
14.30 Workshop Session - Managing the evolving improvement process
15.00 Break
15.20 Session 4: MOVING BEYOND THE SHOPFLOOR - DEFINING AND DELIVERING THE FUTURE OPERATION. Nick Rich, Cardiff Business School, Cardiff University
16.05 Workshop Session - Managing collaboration and step-out programmes
16.30 Panel Session - Delivering sustained results
17.00 Close
Programme and Speakers
Topic 1: Setting the Improvement Agenda
In the first part of the programme, Bill Riseborough from Dow Corning will set out some of the successes of their improvement programme. Bill heads up the continuous improvement function at Dow's Barry site but also provides support for the Dow Corning global improvement focus. His role covers Safety, Reliability and Continuous Improvement in a programme which provides clear evidence that a high performance plant is a safe plant. The Barry site applies a blend of improvement tools including Six Sigma and TPM. We have asked Bill to include an overview of how they evaluate improvement options, allocate resources and set accountabilities to support.
The workshop part of this topic continues the theme of setting the improvement agenda by covering the underpinning systems needed to support development of the improvement agenda including:
Topic 2: Taming Technology
Taming technology is an essential step on the road to Operational Excellence, but delivering it eludes many organisations. This part of the programme will be presented by Paul Wheelhouse of ESS, who as both a manager and consultant has helped organisations to tame technology in industry sectors ranging from those servicing the relatively longer lead time that specialty chemical customers to that of shorter lead time sectors such as food and drink. Paul will present case studies from organisations that have evolved away from the traditional Production and Maintenance role to accelerate the delivery of Operational Excellence. This has been shown to increase improvement programme gains by as much as 50%.
We have asked Paul to include an overview of Lean Maintenance which sets out the role of the maintenance function as part of any improvement process including Lean, TPM or Six Sigma-based programmes.
The workshop session supporting this topic covers the systems that support the stabilisation of operational proceses such as:
Panel Session 1
The speakers from the first 2 topic areas will take part in a panel session to take questions and set out their view of the key success factors to deliver a stable operation.
Topic 3: Holding the Gains
One of the key road blocks to year on year improvement is the impact of organisational change. When key managers move on, often their initiatives wither. The improvement process at 3M at Newton Aycliffe have become so ingrained that when, following a change of CEO, the organisation embraced Six Sigma and then Lean, the TPM process introduced in 1995, was retained and enhanced. Through this, they have significantly increased their site wide performance over each of the last thirteen years.
Derek Cochrane of 3M Aycliffe will present examples from their improvement process. We have asked Derek to set out the key stages in their development and how they contributed to the 3M Aycliffe success story.
The workshop session supporting this topic covers systems that support the change process, including:
Topic 4: Moving Beyond the Shop Floor
A key ingredient of delivering long term improvement is the extension of Continuous Improvement beyond the shop floor. Aligning goals, breaking down barriers between functions and providing the underpinning systems for high performance is an important competence. This topic will be covered by Nick Rich of Cardiff University Business School.
Nick, a founding member of the Lean Enterprise Research Centre (LERC), was fortunate enough to hold one of the elite Toyota Motor Company Research Fellowships (Japan). Working in Japan with 'Toyota and its family of suppliers he witnessed some remarkable improvement and engineering achievements despite their 50+ years of kaizen. Nick has a passion to deliver practical solutions for industry and he has directed much of his energy into working within organisations to gain an insight of how to translate Toyota's success in delivering sustained improvement into other sectors.
The workshop session to support this topic includes:
Panel Session 2
The speakers from the 4 topic areas will take part in a panel session to take questions and set out their view of key success factors for sustaining year on year improvement over extended periods.
Information for Delegates
Click here to register
Venue: Scarman House Conference Centre, University of Warwick. Full details of how to get there will be emailed to delegates with the acknowledgement of their booking.
Registration fees: £450 plus £78.75 VAT = £528.75 and includes lunch, interval refreshment and notes. A 10% discount applies to the above rate for two or more delegates attending.
Hotel Accommodation: Hotel accommodation is not included. Details of overnight accommodation at Scarman (or the adjacent Radcliffe House) will be sent with the acknowledgement of delegate registrations;
Cancellations: In the event of delegates cancelling acknowledged registrations more than 14 days prior to the event a cancellation charge of 205 will be payable. Thereafter, the full registration fee is liable to be forfeited.
Organised by: Conference Communication, Monks Hill, Tilford, Farnham, Surrey GU10 2AJ.
Telephone + 44 (0) 12 52 783111