5 QCO

Status £54 million site turnover that supplies directly and indirectly to automotive customers. Employing over 1500 employees in Europe within 3 shifts, 5 working days pattern. Customer schedule variation generating batch running and high stock holding.

Objective To significantly reduce the change over times adding greater flexibility to production and hence reduced stock holding.

Scope Re establish improved QCO process that can be adopted through out the plant.

Activity Apply by practical example the functionality of QCO on the shop floor.

Outcome 37% immediate improvement in change over with zero cost investment.

58% improvement on 2^nd trial with minimal investment.

91 miles average distance reduction by Setter / Operator in materials movement.

24 hours / day lost compared to experienced QCO results on main tool change over activities in plant.

Results Cross-functional Team involved in QCO realised they had a voice that the

Management listened to.

Significant improvements in QCO activities using simple tools and techniques giving savings and improved material holding.

The QCO became geared to a flexible customer demand offering increased frequency with less volume rather than make to stock.

Exposed issues across plant that benefited from the QCO workshop.