INDUSTRY: Automotive
SERVICES: Creation, training and implementation of a production system
Situation.
An OEM faced repeated failures in the development and implementation of their production system. Management recognized the need for a stronger production system across the facility to enhance efficiency and quality but lacked the necessary resources and expertise for its successful definition and implementation.
ACTIONS.
PHASE 1
Seraph collaborated with a partner consulting firm that was acting as a project lead. Both teams, including our client, collaborated to define and develop the initial focus elements of the integrated operating system.
- To signify a new, focused implementation, we rebranded the name of the operating system.
- Identified the tools that would be the focus of the first year, tiered daily meeting with metric boards, 5S, observations, leader standard work, operator standard work, and waste identification.
- Developed training material around each tool and how it would be implemented within the identified pilot area.
- Developed an assessment with scoring to measure improvements.
- Drove implementation in one pilot area within the plant.
- Took feedback and our observations to modify and improve implementation to enable rollout to other departments within the plant
Phase 2
- With significant accomplishments from Phase 1, Seraph was retained as the sole consultant for the remaining two phases.
- Supported in-depth training sessions, coached leadership teams and implementation of the focused production system tools in 10 pilot areas across the plant.
- Assessments were conducted to establish baseline scores and measure post-implementation improvements.
Phase 3
- Supported training, implementation, and assessments for all remaining departments and shifts across the entire plant.
- Performed assessments in Q3.
- Helped complete gap closure plans from Q3 audit to ensure success in Q4 audit.
- Helped develop and provide feedback on the next set of tools to focus on in 2024 to continue to drive implementation of the production system.
Results.
The entire client management team felt these accomplishments could not have occurred without Seraph’s involvement.
The total project timeline to achieve an average of 1.0 (scale 0-4), basic implementation reached, was 11 months.
- Q3 2023 audit score of 0.61
- Q4 2023 audit score of 1.28, an improvement of 110% from Q3 – Q4
- Q3 audits exhibited a 40% variance in scores
- Q4 audits showed a 10% variance in scores
Audit Highlights
Metric Board & Tier 1 Meeting:
- Successfully closed all major gaps following the gap closure audit.
- Increased leadership involvement to understand the top issues.
Job Observations:
- Achieved a 1.3x improvement, with layered leader observations reinforcing the right behaviors.
- Leaderships involvement directly translated to an increased performance of team members.
GLSW:
- Leaders are effectively using LSW to track customer issues and monitor clean points.
TLSW:
- Realized 5.2x improvement, with headcount enhancements providing Team Leaders the opportunity to focus on TLSW.
Tools created during the project:
– Success and Training Guide
– Leader Standard Work
– Waste Identification
– Tiered Meeting Cadence and Metric Board for Tiered Meetings
