What are the most pressing problems you want to address?

Quality Improvements

Common Problems

  • Customer quality complaints or warranty claims
  • Internal rework, defects, and variability
  • Material recovery or yield issues

Delivery Problems & Long Lead Times

Common Problems

  • Missing delivery dates to customers
  • Big order books and long wait times for customers
  • Opportunity to sell more

Poor Equipment Performance

Common Problems

  • Equipment breakdowns and low throughput
  • Frequent short stoppages
  • High cost of maintenance and equipment ownership

Poor Strategy Objective Completion

Common Problems

  • Unclear line of sight to company strategy
  • Goals and objectives of the organisation not achieved
  • Low level of goal ownership and engagement of staff

Problem Solving

Common Problems

  • Recurring problems
  • Constant firefighting and expediting
  • Fixes that don’t work

Learn more and more

Workload leveling

Common Problems

  • Uneven work across teams and individuals
  • Overall low output
  • People and teams waiting

Materials Storage

Common Problems

  • Damaged and lost material
  • Hard to find materials
  • Long time to pick and pack orders

Learn more

Ineffective Meetings

Common Problems

  • Meetings go on and on
  • Not sure who should attend what meeting
  • No time left to do actual work

Learn more

Team work issues

Common Problems

  • lots of arguments and complains
  • Challenging the leadership
  • Avoiding responsibility

Learn more

Factory Layout

Common Problems

  • Factory moves if current factory too small
  • Motion (people) and transportation (materials) waste
  • Safety hazards and risk of material damage

Workplace organisation (5S)

Common Problems

  • Clutter, outdated and unnecessary items and information
  • Hard to find information, materials and tools
  • Quick regression after focused tidy-ups

Learn more

Poor Standard Work

Common Problems

  • Variable quality and throughput between workers
  • No way to easily instruct, train and assess competency of new staff
  • No way to test new methods for effectiveness

Learn more

Vertical Startup

Common Problems

  • Loss of throughput and quality after commissioning of new equipment
  • Long time before payback of capital projects achieved
  • Staff not properly trained and involved in new equipment

Leading a Change Programme

Common Problems

  • Staff not interested or under-involved
  • No clear plans or milestones
  • Risks and other priorities derail the change programme

Performance Improvement Projects

Common Problems

  • We don’t know what our biggest opportunities are
  • We work on many projects we don’t finish
  • Project benefits are not measured or realised

No Structured Team Training

Common Problems

  • Staff not working together
  • Staff not trained or competent
  • Single person dependency

Learn more

Toolbox meetings

Common Problems

  • Teams not reviewing performance and improving
  • Staff not aware of the plan or their tasks
  • Problems not solved or escalated

Learn more

The Visual Workplace

Common Problems

  • You can’t see at the glance the status of the work
  • We often run out of materials
  • We don’t understand what needs to be done

Learn more & more here

Confusing Leader Standard Work

Common Problems

  • Leaders work on what’s in front of them
  • Leaders forget important (but not urgent) tasks
  • Leaders don’t check the processes

Learn more, more,  & more.

Weak Customer Service

Common Problems

  • A customer’s experience with us depends on who you deal with
  • No agreed service standards
  • Complaints are seen as a ‘problem’ and challenged

Lack of Planning and Scheduling

Common Problems

  • Targets and deadlines often missed
  • No visibility of performance to plan
  • Operational activity is ad hoc and reactive

Supply Chain Issues

Common Problems

  • Sales demand not aligned with operational capacity
  • Everyone working off different numbers
  • Suppliers not delivering to promise

Poor State of Equipment

Common Problems

  • Equipment is dirty and in a poor state
  • Workers don’t care for their equipment
  • Frequent small problems affecting equipment performance

Learn more

Process Improvements Needed

Common Problems

  • Duplication and gaps in duties
  • Problems resulting from gaps elsewhere in the company
  • Disconnected workflow and tasks

Bottleneck Elimination

Common Problems

  • Constraints and hold-ups in the process
  • Work in progress building up
  • Workstations empty and staff waiting

Set up Time Reduction

Common Problems

  • Long times switching from one product to another
  • Lots of scrap and quality problems after start-up
  • Doing long runs to make stock

Insufficient Workforce Engagement

Common Problems

  • People not coming up with ideas
  • Staff only doing the minimum required
  • Low productivity