Ingersoll Rand Case Study
The Challenge
A new Production Director was appointed to initiate a major change programme to drastically improve operating performance and drive the company towards World Class Manufacturing status.
The Method
Bancroft Development for Management and People across all levels and functions; subsequently facilitating focus groups in the workplace.
Benefits And Payback
The impressive achievements have been attributed to the specialist personal and team development 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
- An initial 20% direct headcount reduction and in 2 years 20% indirect headcount reduction
- Moved from 1 manufacturing manager, 4 production managers and 18 supervisors to 2 production managers and 6 section leaders in 4 years
- Going from PUSH to PULL operation with the introduction of wall to wall Demand Flow Technology and from MRP to full Kanban operation
- Introduced Integrated Production Team operation - decentralised empowerment
- Rationalised non effective machine shop operations
- Made significant process changes and performance improvements
- Total manufacturing costs reduced from 23% to 13% of Sales
- Work in progress reduced 10 fold
- Inventory Turns improved from 5.5 to over 10.5
- Average lead time reduced from 7 weeks to 7 days
- Missed shipments to customer request reduced from over 35% to under 5%
- Ability to truly measure suppliers' performance and drive improvements
- No longer any Pick Lists, no inventory allocations to jobs, no Job Transactions or Labour Bookings
