Gray Iron Foundry

180 DEGREE TURNAROUND


PRODUCTION OF: Engine blocks and Cylinder heads

COUNTRY: Mexico

PRIORITY OBJECTIVES:

To implement increased levels of Pro-active Supervision at all levels of management. This would result in:

• improved production levels – higher tonnage production at the end of the production line
• improved productivity levels – higher pieces per man-hour
• reduced operational costs

PVA’S RESPONSE:

The approach focused on the following points:

• To improve the communication flow across departments to increase ownership for production results. This was partly accomplished through the implementation of regular Review Meetings between Maintenance, Quality and Production.
• To involve all managers in the implementation of enhancements to their Management Operating System elements. This involvement not only initiated buy-in, but helped secure ownership to those changes.
• To provide training and coaching to all managers, including the immediate application of all new behaviors ‘on the job’. This was key to increasing their levels of Pro-active Supervision, thereby delivering improved production results.
• To drive results through strong Executive leadership at every aspect of the project. The Executive were provided with the structured elements required to monitor and follow-up on both system utilization and production results.

In addition, some key project activities included: enhancing their Key Performance Indicators to include a productivity indicator in all areas implementing one Problem Solving Methodology that would house all existing Initiatives under one roof clarifying the roles and responsibilities of all managers, and implementing a Manager’s Ideal Day Schedule

PROJECT RESULTS:

Some of the results that our Client achieved were:

• Increased Line Efficiency
• Increased Productivity, reduced Man-hours / Ton
• Reduced Line Downtime
• Reduced Overtime
• Reduced Contractors Costs

In the end, we worked with our client to complete an additional project in another Production Plant.

PERPETUATION OF RESULTS:
Perpetuation is being realized through PVA’s on-going partnership with this company. This Client continues to diligently challenge and question any off-schedule conditions urging his people for timely Action Plans to resolve. Internal Management Personal Evaluations now include assessing their current levels of Management Operating System utilization. The Coordinators conduct regular System Audits, and they analyze and action all results; their Personal Evaluation also include their level of support for the Management System utilization. Furthermore, the coordinators and management team are continuously challenged to improve upon the Management Operating System to better respond to their needs. PVA is also conducting audits in order to support site-wide management system compliance and a successful continuation of their Continuous Improvement Program.