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Kostal staff learning to be lean to improve efficiency
AUTOMOTIVE switch manufacturer Kostal UK is fighting back following a 50 per cent fall in sales by making dramatic improvements in efficiency.
The Goldthorpe-based, German-owned firm, whose customers include Jaguar, Land Rover, Aston Martin, Volvo, VW and Porsche, has been hit hard by the economic downturn and had to reduce staffing levels from 380 to 300 at the start of the year.
Since then, Kostal UK has stepped up its drive to introduce lean manufacturing and reduce waste, cutting scrap levels by 25 per cent and stock losses by 75 per cent, with help from the Manufacturing Masters programme, which is backed by regional development agency Yorkshire Forward.
Kostal put more than 20 junior managers through a City and Guilds programme which involved learning about 'Lean' tools and techniques and then undertaking work-based projects to improve the efficiency of their own work areas, demonstrating the they have learnt.
After being coached by Kerry Cochran of Lean Business Solutions, they were then divided into cross-functional project teams, focusing on achieving measurable improvements in a range of areas.
Kostal human resources officer, Fiona Harrison, said: "We're already seeing some impressive bottom-line results thanks to the efforts of our people.
"Working in cross-functional teams has broken down a lot of communication barriers at Kostal, which has been a real plus point for us. People are now talking to each other across departments to address issues themselves as, following the redundancies, there is no longer someone to 'just report it to and forget about it'."
For more information about the programme, visit www.manufacturingmasters.co.uk
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Thursday 24 May 2012
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