RPC Technologies Pty Ltd The potential offered through continuous improvement RICHARD HUGHES MICHAEL MCLEAN FAICD, CMC Presenters: WHSQ Manager Managing Director RPC Technologies McLean Management Consultants 27 November 2013 Sydney Convention Centre Darling Harbour
RPC Technologies Pty Ltd WHO WE ARE. RPC is a global leader in design, engineering and manufacturing of fibre composites and advanced materials Composite materials are re-shaping our world, and RPC is reshaping the way advanced composites are blended with more traditional methods of production to deliver engineered and manufactured solutions that take performance to the next level.
Transport RPC TRANSPORT Don’t be fooled in to thinking you can replicate the “Toyota Way” Within RPC we realised we have a totally different culture and we can never expect to be another Toyota…..but we can learn from them. We looked within our own organisation to determine our own strengths and used RPC Transport designs and manufactures an extensive those to our advantage range of interior and exterior components for the public transport sector. The assistance we received through Enterprise Connect and our consultant during this process proved invaluable .
RPC TRANSPORT What is the purpose of LEAN? To eliminate waste (8 wastes).
RPC TRANSPORT What was our LEAN leadership strategy? 1. A Lean Vision was defined. 2. A road map and key milestones was developed. 3. Appropriate milestones were set to monitor progress. 4. Resources were identified and available. 5. Working groups were formed (Teams) RPC Transport offers the 6. Ownership of key processes was defined. best of both worlds when it 7. Metrics were established to measure comes to internationally performance. cost competitive supply chain solutions, backed by 8. Individuals were made accountable to the team. Australian engineering, 9. The team is accountable to our Leadership. client understanding and transport know how. 10. The Leadership is accountable to everyone.
RPC TRANSPORT LEAN Principles Lean manufacturing is underpinned by 5 principles: 1. Specify what creates value from the customers perspective (what they want, when they want it at the price they are willing to pay). 2. Identify all the steps along the process chain (process mapping - reduction in waiting, downtime, and waste). 3. Make those processes flow (improve processes) 4. Make only what is pulled by the customer (do not overproduce. Make only what the customer requires – reduction in inventory) 5. Strive for perfection by continually removing wastes (pursuit of perfection – zero defects).
RPC TRANSPORT Steps to LEAN (Our roadmap) 1. AWARENESS - At all levels of organisation 2. 5S - Organise the workplace 3. VALUE STREAM MAPPING INFORMATION and MATERIAL FLOW TASKS* In support, RPC Transport provides solutions in 4. FLOW MANUFACTURING Improve plant layout relation to front ends, wall 5. LEVEL PRODUCTION Reduction of: vestibules, ceiling skirts, • lot sizes modesty panels and toilet modules, refurbishment of • setup times railcar seating, lighting • lead times systems, ballistic and non • inventory ballistic masks, nose cones and coupler fairings. 6. STANDARDISE OPERATIONS TO SUPPORT 8D PROBLEM SOLVING* AND • Improve quality and * Womack, Jones & Roos “Lean Manufacturing” maintenance 1997 page 19 “Value Stream 3 Critical Tasks” • Simplify processes
Transport RPC TRANSPORT What next for RPC Technologies? 1. EC SCIP II to support our Back-end management and support process: • Procurement • Project Management • Engineering and 2. AS9100-C implementation and certification
MMC Pty Ltd is an Enterprise Connect ‘ Tailored Advisory Services’ management consultancy www.mclean-mc.com.au RPC SCIP I summary of TAS MMC assistance : 1. Understand client management systems, strategies, processes in their context 2. Build steering committee, report progress to EC template, define projects and teams 3. Contextualise 4 x AQF CS&P Cert IV modules and use Adult Learning to apply Core Tools to Projects 4. Space team training to enable data collection 5. Complete Team & Personal coaching Tasks
Achieving Customer [Downer EDI] ‘TAKT’ or ‘Beat’ Time targets by…… www.mclean-mc.com.au 1. Determine RPC process stability, ‘MUDA’ in process and capability to deliver 2. Define the “ S>I> Process> O>C ” flows 3. Understand internal / external Supplier inputs, quality, risks, constraints and dependencies 4. Agree what to “Keep -Change- Create” a safe work environment and remove ‘MUDA’ < ‘3S’ 5. Select ISO9001 QMS Process & Procedures that each team will review and improve 6. Use Kanban and ‘ Right 1 st Time’ in all processes
Enterprise Connect SCIP I & II Core “20 Tools” www.mclean-mc.com.au with 8D Problem Solving / ISO9001/4 QMS
Enterprise Connect SCIP I Reporting Templates www.mclean-mc.com.au with TAS AQF CS&P IV Cert Projects and Visual Management reporting templates
www.mclean-mc.com.au Who’s responsible productivity and quality? John Krafcik, now Hyundai USA Strategic Planning VP and ex MIT International Motor Vehicle study and Researcher with Prof J P MacDuffie and “Lean” originator (1987) said: “ design accounts for about a third of the productivity and quality that can be achieved. http://www.just-auto.com/analysis/john-krafcik_id86302.aspx
Dr Juran’s Pareto and Dr Deming – Management is >80% responsible for productivity and quality? www.mclean-mc.com.au
www.mclean-mc.com.au Enterprise Connect – Sustainable Continuous Improvement Program I 2012/13 http://www.enterpriseconnect.gov.au/media/Pages/ClientJourneys/Manufacturing/RPC-Technologies.aspx
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