GKN generates 45% Productivity Savings
from first LEAD Kaizen Event
"The training is allowing us to change the culture of the organisation, and we are now progressing towards having a thinking workforce. We have learnt from a management perspective and are working hard to ensure sustainability."
Simon Robson – Operations Director
"The training has certainly been beneficial. For instance, the Practical Problem Solver has given us a common structure and language to approach our shop floor issues. Now everyone can get involved."
Paul Hogg – Production Supervisor
"We are early into our Lean journey, but we now have the team spirit and knowledge to move forward together."
Ian Spall – Value Stream Manager
"The initial doubts of team members were replaced by enthusiasm upon their return from the course. From a personal perspective, it has has allowed
me to apply Lean Techniques to make improvements across the entire department."
Aaron West – Operations Director
"It was nice that during
the project feedback meeting,
I was able to feel on a par
with senior managers, with whom
I would rarely have contact.
I felt they were actually
listening to me."
Dennis Smith – Production Operative
"For me, witnessing the growth of the learners throughout the course, and seeing their subsequent empowerment and enthusiasm for Lean, has been the greatest satisfaction of the excellent working relationship that LEAD has nurtured with GKN Aerospace. "
Mike Towey – Kaizen Coach
"The biggest boost for me has been the independent projects that have sprung up as a result of the training and the enthusiasm that accompanies them. GKN now truly has a 'thinking workforce."
Simon Gary – Kaizen Assessor
Introduction
GKN in Portsmouth manufacture flexible fuel tanks and inflatable products for aircraft and marine applications. As part of it's drive to embed continuous improvement throughout the organisation, Lean Education And Development Limited (LEAD) have been commissioned to train employees in lean thinking and facilitate the company wide deployment of lean projects through the use of a full time delivery team on the GKN site. This has yielded excellent results and has supported the company
objective of transforming the culture of the organisation. The first kaizen project has generated significant productivity benefits and other potential savings.
Project Title – To improve the bonding process within the Tank fitting area
Objective
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To achieve flow
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To reduce hours
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Increase first yield inspection
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Reduce lead time and inventory
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To create standard work sheets using the process specification provided.
The Process – Using the Kaizen Event Charter
The Event Charter shows "where we are and where we would like to be".
The Analysis
The A3 Practical Problem Solver Template is a structured approach to identify the root cause of a problem and determine solutions.
There is potential to balance processes on the Tank to around 5hrs. Welding would require x2 operators to maintain flow using WIP x1 at each welder. If flexibility exists in Weld and Prep fittings then this would also improve manpower allocation and parts flow.
The Results
The overall effect for the tank product has been dramatic. Before the Lean intervention the product took a total man hours requirement of 165 hours to produce and this resulted in the inability to meet the customer order book and growing arrears.
After the intervention, the total man hours requirement is now 150 hours to produce a product and this has resulted in improved on-time delivery, enough capacity to meet the customer requirement and reducing arrears.
