Covering over 10 areas with just over 50 employees, we managed to implement 5S across the business within a year, with 80% of the areas to the standard required.
We work with businesses at a strategic level. In this particular case, there were 12 annual objectives outlined (too many), with 0 fully completed. The following year, we stripped things back, identified 5 SMARTER objectives. Working with this business, all 5 objectives were eventually completed, effectively trebling the value of the business.
The traditional mindset is when a problem happens, someone messed up. In many cases, this is not true – there is a process that has failed or there is a process that has not been fully understood, along with the consequences of failures. In one case, we managed to reduce the number of problems by over 70% by combining standardisation with effective training methods within a 3-month period.
In this case, product was going out to the customer late and/or not to the required standard. This meant that the Delivery In Full On Time In Specification (DIFOTIS) was 0%(!). Within a 12 month period, we managed to get this up to >95% every month for all products.
If a service or product is not done Right FIRST Time (RFT), then we have an issue. In this case, the RFT was at best 60% on a daily basis. Within 3 months we managed to get this to 100% for all major product lines.