Rockcote Industrial Coatings – Production Team Lean Transformation

Summary

• Team Wide Approach to Lean
• Leveraging Cert III training to drive individual and company gains
• Practical project focus, engaging staff to deliver benefits

Overview

Rockcote enterprises are a well-established and industry leading manufacturer of industrial coating products, located in Southeast Queensland, employing 60+ staff in product manufacturing and distribution. A key improvement strategy identified was to bring together certified training of all its Production workforce and an identified series of improvement projects to drive a step change in its approach to Lean Manufacturing

Efficiency Works were engaged to:

• Deliver an engaging Lean Manufacturing Simulation, key to change management and engagement.
• Develop and deliver a comprehensive Lean Manufacturing Improvement Program.
• Identify specific projects aimed at delivering improved Product and Process outcomes.

These objectives were successfully achieved through application of a team wide comprehensive Certificate III in Competitive Systems and Practices. Conducted over the course of 12 months the Efficiency Works trainer attended site each week to lead and coach Production staff through the journey, ensuring the knowledge and skills transfer was effective.

Working in groups, the 24 Production staff selected a range of improvement projects covering topics including: Value Stream Mapping; Problem Solving; OH&S; Quality and Change Management.

Outcomes

• 12 Staff received full Certificate III qualifications; the remaining staff received Statement of Attainments.
• Significant business benefits derived from 20+ group projects.
• Upskilling staff to conduct future Lean projects.
• Positive win-win for the business, increased capability + SQCDM improvements.