Project Details
Context
The Client is one of Ireland's well known and recognisable brands.
With rising pressure on input costs from the inflationary environment senior management identified risks to competitiveness and decided as part of their change programme to apply best practice Lean thinking to their organisation. This formal productivity improvement project extended gains over two phases covering all aspects of operations. Using Lean & Six Sigma methodologies, Lean Six Sigma training and project life cycle management the transition achieved the objectives of reducing input costs pressures, improving competitiveness and the delivery of a fast, efficient qualitative service.
Efficiency Improvement in Labour
Total Annualised Savings of Over€200,000
Return On Investment After One Year12:1
- Clients: Irish Knitwear Producer
- Solution:Lean White and Yellow belt Training. Work study and Standards leading to a Performance Bonus system integrated with the ERP
- Date:2022-2023
- Sector:Apparel
Objectives and Scope
The use of Lean analytical tools, identified opportunities for improvement in the following areas:
- Work study operational efficiency in production assemble
- OEE for Knitting Machines and Labour efficiency
- Performance related bonus payments integrated and managed within existing IT systems
- QMS System (QMS Policy, Q-Manual & SOPs) – Improved quality, efficiency and training.
- Efficiency of Warehouse Goods in/Goods Out, Lean stock management Runners, Repeaters and Strangers (RRS) & Work studies
- Visual Management - Development of Dashboard displays
- LSS White & Yellow Belt training for supervisory/management team using Tecknic’s Training Academy, leading to ASQ certification standards.
Tecknic's Role
- Performance related bonus payments integrated and managed within existing IT systems
- QMS System (QMS Policy, Q-Manual & SOPs) – Improved quality, efficiency and training.
- Efficiency of Warehouse Goods in/Goods Out, Lean stock management Runners, Repeaters and Strangers (RRS) & Work studies
- Visual Management - Development of Dashboard displays
- LSS White & Yellow Belt training for supervisory/management team using Tecknic’s Training Academy, leading to ASQ certification standards.
Achievements
The reduction of process waste using the above methodologies increased throughputs, improved labour efficiency and decreased unit labour costs. The re-design of existing practices integrated with the ERP established a progressive performance management system.
- Completed Work standards, for warehousing, production & knitting, redesigned jobs and implemented progressive reward Performance Management system integrated with ERP
- OEE combined with labour performance metrics monitoring to achieve productivity improvements with knitting team.
- Introduced QMS to standarise best practice and improve the performance of the production area
- Increased sales & revenue via increased throughput.
- Knowledge transfer of best practice Lean Six Sigma process tools and techniques leading to Certificated supervisors/managers via Tecknic’s training academy.