beyond operation excellence - gavin gillespie, survitec group
TRANSCRIPT
www.survitecgroup.com
• Owned by Warburg Pincus a Private Equity House.
• $400m revenue, 2000 employees, 45 locations, headquartered in
Southampton UK.
• A track record of managing safety and compliance for over 10,000
customers worldwide.
• Largest service station network – Covering 2000 ports worldwide.
• Market Leader in global Marine life raft and Aerospace & Defence Survival.
• World famous brands.
• 160 years of innovation and market firsts.
Marine . Offshore . Defence . Aviation
World Leader in Critical Safety and Survival Solutions
• Marine and Aerospace - Commercial and Military
Our Local Business...
And our customers...
How we work...
Global Spares
...a Full Life Cycle business
Design and Approval
Manufacture and Certify
Installation Service and Distribution
Products that work when all else fails…
• Customer service poor
• Cost base too high
• Poor supplier performance
• Market increasingly competitive
• Traditional work force
• No perceived need for improvement
• Inappropriate incentive schemes
• Institutionalised overtime
• No significant change in 40 years
• Inventory spiraling upwards
• Inflexible people and processes
• Request for more space for growth
Impact on Key Metrics
The Facts
• Turnover £32m
• OTD 56%
• Supplier OTD 38%
• First Pass Yield 80%
• Productivity 66%
• High Inventory 3 turns
• Environmental 25T VOCs pa
Need for rapid
integrated focused
improvement...
Our Improvement Strategy
2009 - Organised Chaos...
Spare
s Ce
ll
Aerospace Cell Marin-ark Cell
Single
Seat C
ell
Lifejacket C
ell
Marin-ark Cell
Cutting/Marking Marine
Welding
Life
jac
ke
ts
S/Seat
Welding
Aerospace
Assembly
Marin-Ark
Pre-test
Se
win
g
Pre
-Se
lect Surviva Mk4
Testing
S/Seat
Assembly
Ae
ros
pac
e
Pa
ck
ing
Marine Packing
Marin-Ark
Packing
Surviva Mk4
Testing
Marin-Ark
Assembly
Ma
rin-a
rk
We
ldin
g
Aerospace &
Marine Assembly
Rented
building
500+m
Layout and management aligned to Value
Streams...
Spare
s Ce
ll
Aerospace Cell Marin-ark Cell
Single
Seat C
ell
Lifejacket C
ell
Marin-ark Cell
Ma
rine
Ce
ll
Life
jac
ke
t Ce
ll
Sp
are
s C
ell
Sin
gle
Se
at C
ell
Aerospace Cell Marin-Ark Cell Marine
Operational
Packing
Cell
Cutting / Marking Cutting / Marking
Training
Room
100m
Marin-Ark
Assembly
Rented
building
• Created a site vision
• Removed the piece work bonus system
• Created a site scorecard
• Developed a performance management system
Empowered and Aligned employees
at all levels...
• Employee development program
• Employee forum
• Kaizen teams
• Community engagement program
Empowered and Aligned employees at all levels...
• Daily communication
• Problems solved using data not opinion
• Continuous improvement now part of daily work
Empowered and Aligned employees at all levels...
Developing a Leadership Capability
www.survitecgroup.com
The purpose of the programme was to
develop management to create a
leadership capability to deliver our
vision
Survitec Group Vision
To be the World Leader
in Critical Safety and Survival
Solutions for the Marine, Offshore,
Defence and Aviation markets
18
Site Vision Exceed customer expectations through
continuous improvement, ownership and teamwork
Leadership Strategy Aligning Management and Leadership,
Developing Capability and Culture to achieve the Vision
Drivers Lean Journey, Site Scorecard
Emphasising The Need for
Leadership, Continuous Improvement, Ownership, Teamwork
Survitec Management Capabilities Customer Focus; Communicating Vision and Purpose; Priority Setting;
Problem Solving; Composure; Continuous Improvement;
Directing Others and Developing Direct Reports
Alignment - Group Vision to Site Capability
Marine . Offshore . Defence . Aviation
• Develop Leadership and Middle Management capability
align the leadership culture to achieving our vision.
• Increase ownership for managing performance
empower all levels of management, create a sense of
purpose.
• Work collaboratively
improve team working within and across departments.
• Support the implementation of continuous improvement
initiatives
achieve engagement across all business functions.
Programme Objectives
Marine . Offshore . Defence . Aviation www.survitecgroup.com
Creating A Leadership Brand & Style
• Motivated
• Engaged
• Caring
• Supportive
• Coaching
Honesty
Integrity
Respect
Can Do Attitude!!
No Blame Culture!!
Sales and Operations Planning
Sales & Marketing
Go to Market
New Product
Introduction
Operational
Excellence
Customer
Intimacy - CRM
Programme
Management Lean
Deployment
Systems Supporting the Business
Strategy
Sales and Operations Planning
Sales & Marketing
Go to Market
New Product
Introduction
Operational
Excellence
Customer
Intimacy - CRM
Programme
Management Lean
Deployment
Systems Supporting the Business
Strategy
Policy Deployment Sales & Ops
Salesforce.com R&D Gateway
Sales and Operations Planning
Site Champions Sustaining the
Systems
• 6S – Weekly audits on the shop floor & offices
Fortnightly report out to Senior Management Team with key
actions identified
• 5Y – Multi functional teams work to establish root causes of
problems
All 5Y activities are recorded and progress monitored
through to completion
• Health & Safety – Discussed daily at each value stream.
Fortnightly report out to Senior Management Team with key
actions identified
Customer • Radical on time delivery: 56% to 95%
• Quality (first pass yield): 80% to 98%
• Lead times: Aerospace 26 weeks to 8 weeks
Marine 8 weeks to 2 weeks
Operational & Environmental • Productivity: 66% to 76%
• Supplier on time delivery: 38% to 98%
• Inventory: 3 turns to 8 turns
• Environmental: 25T VOCs to 5T VOCs
• Floor space: 19% reduction
Financial • Turnover: increased 27%
• Export sales: increased 34%
• Profitability doubled in 2 years
Growth in the face of economic turbulence...
Customer • Radical on time delivery: 56% to 95%
• Quality (first pass yield): 80% to 98%
• Lead times: Aerospace 26 weeks to 8 weeks
Marine 8 weeks to 2 weeks
Operational & Environmental • Productivity: 66% to 76%
• Supplier on time delivery: 38% to 98%
• Inventory: 3 turns to 8 turns
• Environmental: 25T VOCs to 5T VOCs
• Floor space: 19% reduction
Financial • Turnover: increased 27%
• Export sales: increased 34%
• Profitability doubled in 2 years
Growth in the face of economic turbulence...
Closed after 19 years Saving £125K pa
Activities & Achievements
Operational
• UK Manufacturing Excellence Award for Most
Improved Company
• Royal Visit
• AS9100 Rev C Approval
Employee & Community
• Business in the Community Partnership
• Work Experience Support
• Charitable Events
Environmental
• 36 % Gas Reduction
• 8% Electricity Reduction
• 50% Landfill Reductio
• Develop leading hands through Excel
program
• Middle managers projects
• Develop sales growth strategy
• Create sales forecasting policy and align
inventory management system
Next Objectives
• Radical transformation in 3 years
• Fully aligned our team to the needs of our
customer
• Customers feeling the benefits every day
• Grown our market share and doubled profitability
• Created a clear vision of the future
• Enhanced our community
• Reducing the impact on our environment
In Summary
ORDINARY PEOPLE...
ACHIEVING EXTRAORDINARY
RESULTS.