Contact

Sempai Consultancy Services

Derbyshire, UK

​​

Tel: 01335 344 098

russell@sempai.co.uk

stephanie@sempai.co.uk

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© 2019 by Sempai

£800k Saving in quality and productivity

Situation

We were asked by the  Managing Director of a first tier Japanese automotive supplier to upskill Managers and Supervisors in the principles and tools of TPS - control and kaizen – controlling a shop-floor of 800 people. The aim was to create self-reliance and the ability of supervisors to continuously improve their own areas.

Solution

Initially we ran assessment centres to assess competencies (hard and soft skills) and lean skills to identify individual/collective gaps.

 

We devised a 15 day practical hands-on program for 65 Cell Leaders & Team Leaders covering control, 5s, Standardised Work, Waste, Visual Factory, Data Analysis, TPM, Practical Problem Solving, SMED, Line Balance, Layout, Built-in Quality and Area Benchmarking.

 

The training was 75% shop-floor, 25% classroom centred on real problems and the real process. 

Result

Over 3 years, the 65 individuals generated £800k in savings through scrap, productivity, and inventory – a Return on Investment of 3:1. The training was extended to Engineers, Materials other support functions and was recognised globally as excellent development.