Not wanting to be a business that rests on its laurels, Secal Ltd has recently embarked on its next period of change. Where, in the past, the business has been very successful at introducing better equipment and new types of manufacturing process they are now taking continuous improvement to the next level, following a lean methodology. Across the business data is being collected in order to establish the current situation to allow a clear and coherent plan to be created that will detail how the broad spectrum of lean principles and tools will be applied. There is already anecdotal evidence of some improvement occurring in one of the areas that data is being collected, even though the formal development hasn't started, bringing to life the saying "what gets measured gets managed".
Jon Collins, Secal Ltd Operations Director, said
ÂThe journey of lean implementation and training was a natural progression for Secal, as a business we are continually improving ourselves year-on-year. Over the last five years we have reinvested and restructured our business, with both investments in equipment and office developments to further bolster the support we offer to our customers. The implementation of Lean manufacturing philosophy and principles was the next step for us. We have an excellent manufacturing facility here at Secal, and as SecalÂs Operations Director the changes that Lean will bring to the business really excite me. Lean enhances performance of the business through the efficiency, culture and process improvements. As with everything we do here, the Lean implementation programme is very much a team effort we are all proud to be part of. Working with a Lean manufacturing mentor of the calibre of Simon Danks is proving invaluable to myself and the whole team here at Secal. What are the reasons for implementing Lean Manufacturing? To improve the overall service our customers receive ... It really is that simple!Â
Simon Danks of Mobius Improvement Ltd, who is facilitating change and coaching the business said
"The potential for Secal Ltd to benefit from applying the philosophy, principles and tools of a lean approach is significant. The owners have built a strong and thriving business, a great platform from which to now drive change through its people, maximising the potential of the existing equipment and processes. The initial response from members across the business has been very positive and I look forward to seeing how they apply all that they will learn in order to better support their customers as well as securing a stronger future for themselves."
Our photo is from The Lean Workshop 19th April 2016
Our staff learnt the benefit of the 5 lean principles!
1. Understanding value
2. Understanding value stream
3. Understanding value flow
4. Pulling at the rate of the customer
5. Pursue perfection
Staff learnt the objectives by forming a timed production line. They reviewed their performance and discussed possible improvements. The team eliminated non value adding waste, improved the flow of parts through process and finally made parts at the rate customers required them. The production line saw a dramatic difference of 60% when changes were made.
Introduction to a new way of thinking
On the 9th May Jon Collins and Simon Danks introduced the Lean business improvement programme to Secal. Here is an overview of what we learnt.
SecalÂs overall plan
The overall plan is to change our business culture, to increase quality and reduce waste in every sense of the word. Everyone will have a role to play in making the changes that will improve efficiency and quality whilst reducing costs; this will maximise the potential of the existing equipment and processes here at Secal, reducing customer lead time and giving us a more productive and efficient business.
How will Lean benefit the business.
With an increase in quality and efficiency we will see an improvement in on time deliveries to our customers, this will in turn result in happier customers and a happy customer is one that returns with more orders. The increase in efficiency will also result in a more profitable business to see us through our quieter periods and should also enable reinvestment in people, training and equipment.
How Lean will our staff benefit as individuals?
All staff will have a cleaner, more organised and efficient workplace. It will be nicer environment to work in with more communication across all levels and more emphasis on training and personal development. We will work for an excellent company of the highest standard, with reduced stress-levels and increased job security and satisfaction.
What will be asked of our staff.
What we will ask is simply open minded support, cooperation and enthusiasm, a willingness to learn and help us improve our business  . their business!
