Gemba had to fully understand the business needs and operational objectives before every project commences to ensure both parties appreciate the task and expectations. Gemba were then able to tailor the project to focus on creating capacity for the plant and improve workflow. A Pilot approach first established the real-time performance metrics from a single production line and shared a visual representation to all stakeholders of the line with the sites established KPI’s that everyone would understand. Gemba then used the data to identify the gaps to standard and work with the shop floor teams to root-cause and remedy these. Andy Johnston, the Plant Manager at Manuli, was keen to understand the true picture of the current state of the operation and the size of the opportunity that Gemba identified. Andy himself got first-hand insight to the Gemba Rapid Improvement Programme (GRIPs) by joining the interactive workshops on the shop-floor, analysing the processes and making changes using the real-time data Gemba was producing.
Gemba ran several GRIPs working with the shop-floor teams across shifts to fully appreciate the challenges and opportunities and how best the Gemba CONNECT system would complement and help sustain the operational improvement. Manufacturing Software solutions are common but where Gemba differed was how they supported the business and Users in the improvement journey. The CI Services provided by Gemba ensured we were able to sustain the improvement.
The target improvement was identified as 5% when in fact the Gemba GRIP delivered a 9.5% improvement that we have been able to sustain and continue to improve upon. This new improved process has now been replicated across other production cells enabling us to bid and successfully win new business that we can confidently fit within our newly created plant capacity, securing future employment and achieving our business growth objective.