British Aerospace Case Study
The Challenge
British Aerospace had a 'World Class Mission' to achieve a more competitive position through major culture and process change, comprising manufacturing and procurement. The Head of Manufacturing stated that the company suffered from:
- Being World Class at Fire Fighting
- High Utilisation of Machines
- High Levels of Inventory
- Long Lead Times
- Quality by Detection
- Poor Delivery Performance
The Method
Bancroft developed people across all levels, functions and sites, providing Aerospace with the ability to achieve their objective. Involving the people and introducing a 'Team Culture' was the main force behind implementing these major process changes.
The Bancroft Personal Development Included:
- Senior Management
- Team Leaders
- Operator Personal Development
The Development Programme
- Lead role in producing and facilitating the Cross Functional, Cross Site, Team Development Programme for Supplier Collaborative Agreements. - £9m Improvement
- Formulation and practical running of Graduate and Management Development Programmes
- Facilitation of the Culture Change Programme for the Implementation of Lean Practices, KPS and JIT including benched marked cross-functional teamwork programmes
- Design and Implementation of Leadership Assessment Centres
- Performance Review Training
- Management and Unions Partnership Programmes
Benefits, Payback and Achievements
The impressive achievements have been attributed to the specialist personal and team development programme, provided by Bancroft. Involving the people and quickly developing their skills to operate in a team working culture, across all levels, functions and sites proved the key to success.
This comprehensive development provided the people with the skills to commit to major change and to accept the support of the operational consultants.
The Achievements
- Reduction of inventory - £65m to £12m
- Reduction in Lead Times - 84weeks to 10weeks
- Increase Stock Turn - 2 to 10
- Increase Added value ratio - <1% to >30%
- Quality Yield Improvements - 80% to <10,000ppm
- Reduction in Suppliers - 4,000 to 757
- Reduction in Set-Up Times - 4 Fold Reduction
- Improved Productivity Levels - 35% to 45%
- Significant Improvement in Cash Flow
- Reduction in Functional Barriers - Team Culture
- Beck & Pollitzer Award For Excellence
- Best Factory Award
- Inside UK Enterprise Reference Site
- National Training Award
- £9m Improvement In First Year
