2010
Griffin’s Foods Limited used KT’s Step Change model to improve the Operational Efficiency of a new production line which was struggling with high waste, high downtime and planning deficiencies. A series of improvement initiatives were selected from a detailed analysis and implemented using KT processes.
At the conclusion of the project the line had achieved a 30% improvement in Production Rate and a 47% improvement in Operational Efficiency. This step change improvement represented an ROI over a 12 month period of 12:1.
Ladrillera Santafe, Colombia’s leader in the brick industry, was tackling performance issues throughout its production process, resulting in higher costs and delays, especially when the market was reactivated and started to grow. Plant Managers and Supervisors, trained in KT PSDM, started working on the most pressing issues.
After two months of process application, results showed an increase of 6% in the production rate of one line, and a reduction of 56% in the rejection rate of another line. The combined results of the improvements to date, will allow for US$1.25MM in additional annual sales.
UBE Group’s timely use of KT processes in a Pure Lactam Condensation Tube (1330 E7-2) chemical leakage situation, enabled the plant to avoid an unplanned shutdown and deal with quality issues, resulting in cost savings of around US$100,000.
Using the KT Problem Analysis process, the maintenance team focused on gathering relevant factual information, systematically eliminating irrelevant possible causes, collaborating and saving time in finding true cause.
Johnson Controls (JCI) is a global company providing products and services through three divisions – Power Solutions, Building Efficiency, and Automotive Experience. Employees throughout Johnson Controls have been trained in KT PSDM, and many senior managers have been certified as KT Program Leaders.
“Triple Certification” at JCI includes JCMS Lean, Six Sigma, and Kepner-Tregoe. Recently, by applying KT Decision Analysis, JCI was able to save US$5M in choosing a software provider. The leadership at JCI remains committed to using KT processes throughout the company to achieve positive results.
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