The Company’s operating policies commit it to continual improvement of its performance, and prior to working with Gemba, staff were using spreadsheets to record manual stoppage data. However, the data was flawed as minor stops (below 15 mins in this case) were omitted, staff sometimes forgot to record data, and efficiency KPI’s were generated based on an average monthly tonnage rather than actual production output. The team wanted to address these issues, get an accurate view of throughput and also implement some visual management techniques. Gemba Solutions was chosen to help them based on the software solution proposed and its ease of use, the attitudes of its staff and value for money of the complete solution.
Singleton Birch report that both throughput and uptime have so far increased by over 50%. Along with this, Gemba has helped to spread the continuous improvement message across the site - a step-change that has been achieved on the back of the consistent and unambiguous data that the software has presented. Benefits have been so significant that Singleton Birch are now rolling the solution out across the whole of the quarry and kilns.