Case studies
BHP Billiton Iron Ore
Mining
Critical Chain in large Mining Projects
Summary of Success
Productivity improvement of more than 33%. Engineering work finished an unprecedented three weeks ahead of tight schedule.
...it forces detailed planning and lead thinking. Prioritises today's work. Integrates well with Lean and Six Sigma.
Lloyd Jones, Project Manager
Cadbury Schweppes
Manufacturing
Drum Buffer Rope
Summary of Success
Our engagement resulted in higher production volumes, significant reductions in inventory and work in progress and several production process flows have been optimised, eliminating double and triple handling.
The approach allowed Cadbury to take a fresh approach to production planning and process optimisation and has engaged the workforce in looking at production process improvements more pro-actively.
Erik Siedler, Business Unit Leader
Smorgon Steel
Manufacturing
Drum Buffer Rope
Summary of Success
Constraint analysis identified the bottleneck of the system. Then by implementing Drum Buffer Rope and subordinating the system to the constraint, WIP was halved and due date performance was improved three and a half fold over a period of five months. This resulted in a 63% increase in profit.
The Ensemble approach gave the operators and managers the tools to rethink their operations, put some science around the method and belief in the opportunity for improvement. The process is now being introduced to our forging business.
John Gillespie, Works Manager
Sunbeam
New Product Development
Critical Chain
Summary of Success
Since the introduction of Critical Chain and Concerto, the business has met its returns target on all new product delivered to market.
Osh Kosh B'Gosh
Design
Critical Chain in New Product Development
Summary of Success
The impact on visibility has been dramatic. It has made managing the whole area a lot better and a lot easier! …. now everyone knows what is meant to be done when, so designers work on what is most important, not what they like doing. We can see straight away if things are running off-track, long before they turn into disasters, so our planning is much more proactive than the reactive method we used to use.
Philip Zylstra, Managing Director
Freedom Furniture
Supply Chain
Replenishment Solution
Summary of Success
Productivity improved 22% with no additional labour or capital resource. Improved due date performance and reduction in stock levels.
“Establishment of KPIs was well executed, appropriate and addressed glaring gaps. The Thinking Process exercise allowed us to reinforce management’s ideas and goals all on one page. It has enhanced the throughput operating culture, with all employees speaking the same language.
Geoff McIntosh, CEO
Skye Group
Manufacturing
Drum Buffer Rope/Critical Chain
Summary of success
Turnover Doubled, Inventory halved, happier staff and best practice due date performance
“ We are delighted with the results . We have addressed our inventory and sales cycle issues. We have the best due date performance in the business. Ensemble are excellent facilitators – the best I’ve seen”
Phillip Zylstra, Managing Director
Sheridan
Manufacturing
Thinking Process / Drum Buffer Rope
Summary of Success
Sheridan reduced their inventory and as a result customer satisfaction increased. Staff performance and satisfaction rose across all sectors of the business.
Stock servicing levels in the high nineties are now achieved and make to order is 100% on time in full.
The success for TOC was definitely enhanced by the buy-in from employees, obtained through participative Thinking Process workshops.
Sheridan Australia
Australian Country Spinners
Manufacturing
Constraint Accounting/Thinking Process/Drum Buffer Rope
Summary of Success
Within a short time frame throughput had increased by 171%, inventory levels had reduced by 40%, exports up by 27% and profit exceeded 25% of ROI
Ensemble has enabled ACS to do what we thought was impossible, dramatically increase our production using few extra resources. The approach Ensemble bought reinvigorated our people and enabled them to look beyond our traditional functions and processes from a fresh perspective
Brian van Rooyen, CEO
Quintrex
Manufacturing
Thinking Process/Drum Buffer Rope
Summary of Success
Based on the outcomes achieved by engaging Ensemble the business has been able to expand internationally with distributors in the lucrative European and North American markets.
Ensemble’s involvement enabled our staff to significantly increase output and efficiency and by allowing us to plan and manage the run rate we could look to new markets
Paul Phelan, Managing Director
Gluck
Customs clearing and freight forwarding
Drum Buffer Rope
Summary of Success
Gluck have been able to identify an additional 25% of additional productive capacity without any addition resource required.
System improvement enabled Gluck to manage by exception and provide superior service levels to their customers
Ensemble has guided us through a review of our operations, understanding the constraints and drivers of our processes. Significant incremental increases are being each month in our quest for overall productivity gains of 25%
Steve Bradtke, GM Operations
