Driving Profitability – World Class Crewing

Driving Profitability – World Class Crewing

➤   Are you aiming to increase your Profitability, Run Leaner and produce Better and More with Less?

➤   World Class Crewing is a Lean Methodology executed to create breakthrough results in your Profitability journey and to enable your organization in optimizing Labor cost $/unit and people productivity measure unit/HR   .

➤   Our Competent team of consultant and Scholars will lead your team in driving the results through evaluating 6 areas integrated within a Value stream mapping and DMAIC workshop:

Predicted Gains

✔   RAMs (Roles, Accountabilities, Measures)

   -Workplace / Line/ Equipment Layout

✔   -Current State Process Flow & workforce assignments

✔   -Employee Diagnostic- Skill Matrix

✔   -Tasks Evaluation

✔   -Equipment Condition and possible automation

✔   10-15% improvement on $/Unit people cost.

✔   15-20% improvement on unit/hr. people productivity

✔   Standard Work & Continuous Process Flow.

✔   Efficient, Engaged and Empowered Work force.

✔   Automation Solutions and Interfaces.

✔   Efficient utilized production lines

Our Methodology

Define

✔   The current KPIs Labor Cost $/unit and People productivity Unit/Hr.

✔   The problem, the scope , the team, the business case and impact

Measure

✔   Labor Cost $/unit and People productivity Unit/Hr

✔   RAMs (Roles, Accountabilities, Measures)

✔   Workplace / Line/ Equipment Layout

✔   Current State Process Flow & workforce assignments

✔   Employee Diagnostic- Skill Matrix

✔   Tasks Evaluation

✔   -Equipment Condition and possible automation

Analyze

✔   Brainstorming , Nominal Group Technique

✔   Problem solving Techniques: FMEA, 8D, 5 whys,BDA, FISHBONE

✔   Effort /Impact Matrix , SWOT

Improve

✔   Eliminate non added value / Merge / streamline Tasks

✔   Standard Work Strategies

✔   Continuous process Flow strategies

✔   redesign / Change equipment layout

✔   Improve equipment reliability

✔   Automating tasks

Control

✔   Future State process flow Map – work force assignment

✔   Workforce Training

✔   SOP’s

✔   Revised RAMs

✔   5S, Jidoka, Andon , Poka Yoke

Related Case Study

Case : Chools was hired by 100 fortune Food and beverage company in MEA Region to drive and develop its Productivity, Lean Six sigma, performance and TPM journey. World Class Crewing was one of the methodologies used to drive profitability.

Act : Chools Consultants conducted WCC across 3 of the MEGA plants in MEA- 6 lines. Our consultants leveraging a Value stream mapping & DMAIC methodology conducted the 6 mentioned assessments and used several Lean problem solving and analysis tools and above all trained the team.

Results : An annual reduction in Labor cost of 13% and increase in people productivity of 17% Case/Hr was achieved.

Driving Profitability – World Class Crewing - Case Study

Problem

A Leading Beverage producer with an annual NOPBT of $40MM hired Chools to increase its profitability. It was found through our initial Deep Dive event that the Glass returnable bottle CSD line had the highest manufacturing overhead expenses in comparison with the other production lines, where Labor costs constitutes 80% of its MOH (35 employees). The producer budgeted annual operating plan was 0.172 $/case, and their actual was 0.185. Our objective was to assist our partners in meeting and exceeding their annual operating plan.

Solution

We found that the best tool to drive our objective is World Class Crewing. Our team used the WCC tools and assessments: Employee Diagnostic, RAMs evaluation, process flows evaluation, Line Layout, Equipment Condition As is audit and Skill Matrix.

2 potential machine orientation changes were identified that would enable 1 employee to operate them instead of 2 (each machine).

 8 major equipment defects and reliability issues were identified that as fixed would not require a dedicated Mechanic for the line and increases the productivity of the line crew.

 One non added-value step on Glass inspection before the bottle washer was eliminated reducing 1 headcount.

 The criteria for receiving the Returnable glass bottles from the market was reviewed and optimized increasing the productivity of the crew on the GRB inspection line reducing the # required/shift.

Results

5 crew members were displaced to open roles on other production lines so that the labor cost on that line was reduced by 25% increasing the profitability of that line and $/case improved from 0.185 to 0.165 $/Cs.

Employee productivity Case/EE-Hr increased by 26%.

Problem

A Dairy products Manufacturer with an annual production of 544MM ounce was aiming to increase its profitability through Improving Labor cost. The total cost $/case was 0.19, of which the labor cost was .09$/case vs an annual operating plan of .06$/case.

Solution

We found that the best tool to drive our objective is World Class Crewing. Our team used the WCC tools and assessments: Employee Diagnostic, RAMs evaluation, process flows evaluation, Line Layout; Equipment Condition As is audit and Skill Matrix.

The two driving action plans for the improvement was:

Create specific RAMs( Roles , Accountabilities, Measures ) for each role and optimizing the crew utilization based on the tasks. In addition, a Skill Matrix was developed to train all crewmembers to have the flexibility to move between production lines.

7 inspection steps were Automated to reduce 14 required employees.

Results

14 crewmembers were displaced to open roles in other plant areas.  Profitability was increased by 15% by reducing the Labor cost 0.06 $/Cs.

Employee productivity Case/EE-Hr increased by 21%.

WCC – Templates 1

WCC – Templates 2

WCC – Templates 3