Saturday, January 30, 2016

Closing the “Last Mile” of Efficiency

Performance Management holds different priorities for corporate management and plant-level stakeholders. Corporate stakeholders tend to emphasize technologies that provide visibility so they care more about the “I” as in Manufacturing “Information” Systems. In contrast, plant-level stakeholders tend to emphasize technologies that provide control so they care about the “E” as in Manufacturing “Execution” Systems (MES) capabilities. These two perspectives converge when both stakeholders realize the need for an integrated approach to tackle the “last mile of efficiency.”

What we have observed is that the vast majority of companies have put in place good practices. Although many of these practices are largely manual or paper-based, they have made progress in their efforts to reduce waste. But these paper-based processes often “hit a wall” when they reach the 90% mark on the three “OEE pillars” because losses at this point often result in “micro-stoppages” that are akin to profits “bleeding by a thousand paper cuts.” Two core challenges must be addressed: Knowing (seeing events in context) and Acting (to recover in a timely manner.)


When companies approach this “last mile” threshold, it changes how they view the scope of the solution because they realize visibility (even if it is real-time) isn’t enough – real-time control is equally important to enable real-time KPI management via a closed-loop process. Specifically, work process integration becomes critical to empower front-line workers to “fix problems at the source” as illustrated below:

We have found that there is “maturity” journey that companies go on in order to achieve efficiency.  We developed the following framework as our internal assessment – it is meant to give an idea of where a company could be in their evolution.

Too often companies are not align on where they are relative to systems, culture, and alignment between the different aspects of the company.

Performance Management Maturity Model

As we have stated many times Operational Excellence is not a project it is journey, and we have found having a framework built on experience as the best way set up the path for companies.
Where do you fit in this maturity road. 

Monday, January 4, 2016

2016 the turning point in the Operational Work Transformation!!

Will this statement stand true to the operational execution world we live in, probably only time will tell, but based on the trends I outlined at the end of 2015, and looking forward I believe 2016 provides the opportunity.

By the way, welcome to 2016 may it be an exciting and productive year!
The holiday break it provides a time to reflect and discuss, and in one conversation my last blog was raised and really “how much transformation was happening?” Initially, I thought it was a comment against the trend we are seeing with the “Operational Transformation”, but this was a friend working in a major food manufacturing company. His comment was actually the momentum of change is well underway, and happening at increasing pace.
There were 4 areas that he felt his business and associated industry where trying grapple with to stay ahead:

1/ Agility of effective, valued products and brands to the market (which he stated was regional, eg specific tastes of similar products changed by region and so your go to markets, packaging, etc. His example was around cheese how the tastes in say Mexico for cheese are totally different to Australia, and then Italy. This leads the increased importance of regional new products vs global new products, and effective speed and cost of innovation, execution and introduction.. So the challenge of “new product Innovation” and then “New Product Introduction” and delivering it to the market at the correct margin to be competitive in timely manner is a whole focus. His comment was this is the core competitive advantage that his company identifies, and must keep driving while dealing with the other transformations happening.    

2/ Operational Workforce transformation: He agrees with me that too much focus has been on the “aging workforce issue” and that most of HR and Operational teams have missed the bigger transformation, and that is the one of new generation work methods and transformation in workspace that goes with it. He felt like his company woke up to this mid way thru last year when they could not just not fill positions, but are having significant challenges in retaining talent, not within the company but in roles. He felt like initially people thought that would just get a transition to a new workforce yes younger of different experience. But they had not realized that way in which people will work, think, interact, and gain satisfaction will also change.

3/ “Planet Awareness, Image”: this one was an interesting discussion, as he raised it as a real strategy for evolving the brand of the company to been seen as proactive to the environment, to attract further “feeling satisfaction” of customers. He also stated that government regulation, and increasing costs of disposing of waste, and energy costs also are now seen a significant bottom line costs, and must be managed more efficiently. But during this discussion, it was also clear that the perception of being “proactive to the environment” in use of energy, carbon footprint, environment etc was also a key strategy for attractive talent to work in the company.

4/ Transparency across the total product value chain, “end to end”. This strategy was about tractability and making sure they happy with brand all the way to customer, but also about cost as they were “outsourcing” increasing amounts of the value chain. But this did not mean they lost responsibility for product while in “outsourced manufacturing partners” execution. The transparency across the supply chain enables increased flexibility and lower costs through inventory reduction.
These 4 strategies are combined with the current strategies to increase plant performance utilization and lower cost of materials through waste /loss reduction.
When you sit back and look at these strategies a constant set of pillars came up in the Operational Solution approach:

·       Everyone having access to information and knowledge no matter their state or location, this means internet becomes a part of the solution backbone.
·       Cyber Security is very much top of mind, both in strategy to secure,  manage, to contain cost and risk.
·       Data validation/ and contextualization, if transparency and faster decisions are required how do you gain consistent information across different sites. \
·       Delivering a new “operational Workspace/ experience” that has embedded knowledge that does not get stale, and enables imitative learning for a dynamic and collaborative workforce.

As the night conversation went on it was clear that the 4 strategies was really about changing the way in which the company manages and executes operational work, no matter how big or small. But becoming in control of not just the planned product work, but the day to day, minute to minute work at the different levels of the operational loop.

Based on the trends of 2015, this long conversation, I wonder if we will see 2015 as the year people recognized that needed to rethink how they handling “Operational Work”. With 2016 becoming the year where momentum continues to grow on projects turning to programs, that span plants, and value chain and an increasing amount of companies put teams, strategies and programs in place to evolve their operations to transform the way handle “operational Work”!


You might ask what about “big data” and the “internet of things” but these are technologies that will be part of the enabling system for a  new operational solution.