Transcript Slide 1

The UK Government’s
Manufacturing Advisory Service
Presentation by
Brian Sainsbury
Joint Managing Director, PDA
UK Manufacturing Advisory Service
MAS
Opportunities for Bulgaria
•
•
•
•
•
•
•
Good business environment
Favourable tax legislation
Exchange rate stability
Attractive labour costs
Highly qualified people
Developing economy
Good culture
February 2009
March 2009
Report – BG Human Resources Development Dec 2008
Issues
to address
•
•
•
•
•
Labour migration
Corruption issues resolved
Culture of improvement
Low productivity levels – 32.7%
Effective change management &
improvement to raise productivity
• Training to raise adaptability of employees
UK Manufacturing Advisory
Service MAS
Suitability of similar
scheme for Bulgaria
MAS – Key Points
• Established 2002
• Funded by UK DTI (now BERR) and the
Regions
• Strategic objectives of Government’s
Manufacturing Strategy
• Offers practical information, advice and
assistance to manufacturers, focusing on SMEs
Delivery Structure
The MAS Regional Centres
12
Team
Network
National
Regional
of Specialists
ofwebsite
registered
Centresand
in additional
each
helpline
region
specialist support
MAS Scotland
MAS North East
MAS North West
MAS Yorkshire & Humber
MAS West Midlands
MAS East Midlands
MAS Wales
MAS East Of England
MAS London
MAS South West
MAS South East
The MAS Core Services
• Level 1 – Information, signposting and advice (free)
• Level 2 – One to two day free diagnostic advisory visit
by MAS manufacturing specialists (100% Funded)
• Level 3 – Training events – general and company
specific, master-classes, seminars
• Level 4 – In-depth consultancy support at costs
affordable to SMEs – 10 - 30 days of work, 50% funded
• Level 5 – Referrals to other sources of assistance and
expertise
MAS In-depth Support
• Productivity improvements, Lean Manufacturing,
Process improvement, etc
• Team building
• Improving plant layout and space utilisation
• Cutting work in progress
• Improving quality and delivery
• Helping with materials selection & testing
• Design & innovation
MAS types of Support
Process and Value
stream mapping
Factory layout Improvements
Cellular Manufacture
Introduction of 5S
Key Success Factors
•
•
•
•
•
•
Designed by manufacturers for manufacturers
High quality manufacturing specialists
Easy to access, no red tape,
Hands-on, and practical
Flexible approach to problem solving
Focused on real benefits
• Skills transfer for sustainability – helping
companies to help themselves
Recognised by UK Government as being one of the
most successful business support schemes ever
introduced.
Summary Facts:
• SME focussed support to improve productivity, quality,
innovation
• Non-bureaucratic ‘hands on’ practical support
• Cost to Government over 7 years Circa £65M
• 24,000 diagnostic reviews and 8,000 in depth company
projects conducted
• Impacts ‘Value added’ savings in companies £500M
‘MAS has proved able to deliver real benefits to UK Manufacturers.
I congratulate all involved with MAS for the success it has
achieved’
Rt Hon Alistair Darling Secretary of State for Trade and Industry
MAS Case Studies in the UK Clothing and
Textile Industry
• Introduced New Factory
Layout
• 30% reduction in lead times
• More streamlined & efficient
MAS Case Study Textile and Clothing
Industry
Background
Griffin Nuumed equestrian fabric
manufacturer used advice from
MAS to invest in technology which
increased productivity and
improved staff morale
Manufacturing Concerns
Sales growth of 30% in the last
year meant that there was a real
need to improve productivity and
start to use technology
MAS Diagnosis
Introduce computer controlled
fabric cutting machine. Digitise
and store existing templates.
Use design software to introduce
new designs. Improve layout to
reduce handling and waste.
Results
Productivity increase of approximately 40% in the
cutting area. Improvement of quality and accuracy of
cutting. Improved team work and morale. Reduction in
material movement and manual handling.
MAS Case Study Textile and Clothing
Industry
Background
Uniform World is a manufacturer
of corporate wear, established in
the 1970s. It has a turnover of
£370,000 PA and employs 13
direct staff.
Manufacturing Concerns
The Company was having to compete
with an influx of lower priced imitation
imports, putting pressure market and
profitability.
MAS Diagnosis
MAS set up workshops that examined
key aspects including how to increase
awareness of the Company new markets
and creating its own bespoke products
Results
The Company has successfully re-positioned itself in the
premium sector of the corporate wear market, developed
key relationships within the supply chain and developed
value adding solutions The business has grown by almost
50% in turnover and is achieving better margins.
MAS Case Study Textile and Clothing
Industry
Background
K Stevens (Leicester) Limited have been established
for over thirty years as manufacturers and suppliers of
quality tapes and trims
Results
The MAS intervention created a net saving
over £40,000 when compared to their original
selection of software and hardware. The
company also have a clear plan to develop
the European market for their products
Manufacturing
Concern
The company needed
advice on quality and
the implementation of
a computerised
management control
system.
MAS Diagnosis
The MAS specialist Practitioner
helped the company to coordinate their for ISO 9000 and
the procurement of a
computerised management
control system.
Lean Manufacturing – real case study benefits
Measure
Before
After
> 300
~ 25
~ 10-15%
~ 0.5%
Disjointed production
& high stress
Stress eliminated
Low-difficult
High - easy
6 Average cycle time (days)
~ 23
2 to 3
7 Ease of training / understanding
low
High – multi-skill
normal
8 On-time in full to customer
25%
>99%
~ 1000
~ 250
1 Distance travelled (m)
2 Rework / reject loss rate
3 Pressure / employee fatigue
4 Feel-good factor / team-working
5 Communication at all levels
9 Floor-space required (sq.m)
The MAS Process
MAS
Quality Check on
Improvement
Objectives
Manufacturing
Review
Terms of Reference
(Proposal)
Quality Check on
Improvement
Objectives
Focused
Manufacturing
Review
• Improvement outcomes
• Measures
MAS
• 10 days
Manufacturing
Intervention
• 30 days
Results /
Outcomes
• Expectations
• Satisfaction
Agreed
with Client
Company
MAS
Quality Check on
Improvement
Objectives
Manufacturing
Review
Terms of Reference
(Proposal)
Focused
Manufacturing
Review
• Improvement outcomes
Trial
Business &
• Measures
Manufacturing Review carried
out in a Bulgarian Garment
• 10 days Company –
MAS Manufacturing
Manufacturing
• 30 days 10/03/09
Tuesday
Intervention
Quality Check on
Improvement
Objectives
Results /
Outcomes
• Expectations
• Satisfaction
Agreed
with Client
Company
BG Company feedback
• Interesting to hear different opinions from outside
• Good to have an external view with different eyes
• Agreed on identified levels of efficiency and
productivity improvements
• Also agreed on suggestions to address this
• Appreciated the two-way process – Good Will
approach
• Now feel energised to address improvements
identified
• Would like help and support in implementing
proposed changes
• According to UK MAS clients
their business improves by an
average of 73,700 GBP per year
when they undertake a MAS
project
• These improvements are likely to
increase and repeat year after
year
About us
Assystem UK
PDA
The Proposed project
Assystem UK who we are
• Part of the Assystem Group
• Offices throughout Europe, Americas and the
Far East
• 8000+ employees €650Million T/O
Assystem UK relevant experience
• European Commission
– Provided the Technical and Management teams for the
SPRINT, INNOVATION and LIFT SMEs support programmes
• UK Government
– Development and management of the UK’s Manufacturing
Advisory Service Programme MAS
– Secretariat of EUREKA FAMOS programme
• UK Regional Development Agencies
– Development of a Productivity support programme for SMEs
• EC Accession countries
– Latvian Innovation Agency Pilot support programme to improve
in manufacturing SME
– Estonia Enterprise SME Grant programme
PDA Consulting
• Established in 1982 as a consultancy and training
organisation,
• PDA involved with government grant schemes since
1987.
• Strong experience assisting UK manufacturing
companies improve performance at all levels.
• Since 1997 significant involvement with Bulgarian
manufacturing companies supplying UK customers
including : BARBOUR, CORUS, UMBRO, NEXT and
TESCO.
• 35 people in UK on consultancy and admin
• 45 people employed in Bulgaria controlling materials,
technical and production processes.
PDA Consulting Bulgaria
• PDA Manufacturing BG Ltd established in1997 to
manage UK customer orders at Bulgarian
manufacturers.
• Responsibilities include planning, technical, quality,
progress, logistics and finance.
• PDA currently working with over 40 BG companies in
Clothing, Foundry and engineering products.
• BG Productivity now a key issue with UK customers
A Manufacturing Improvement
Programme for Bulgaria
Our Goal
A National programme for Bulgarian SME
manufacturers with local delivery and real
impact
Based on the highly successful UK Government’s
MAS programme
Thank you for your attention
Further information or copies of
presentation slides available