Achieving excellence through
accelerated learning
Achieving excellence through
accelerated learning
Midlands-based Burcas provides specialist manufacturing process solutions to a range of industries. TEC had already guided Burcas through to successful AS/EN9100 certification and identified that the synchronization of strategic suppliers would be central to the continuing success of the company. SC21 was chosen as the framework and Lean Six Sigma provided the improvement process and essential 'tools'. The aim was to quantitatively improve the overall quality, cost and delivery performance of itself and its key suppliers. In the process selected individuals from Burcas and the suppliers were trained and qualified as Green Belts and are continuing to use their skills to undertake further projects and to train others. Separate Champion Training was also provided for senior management along with yellow Belt training at shop-floor level to ensure support for the projects from data capture and implementation perspectives.
During the diagnostic phase TEC identified potential improvement projects and specific training needs along with identified "change agents" within each of the participating companies. The Lean Six Sigma training programme extended over a 12-month period with mentoring support visits provided to each of the suppliers to authorise every DMAIC 'tollgate' to ensure completion prior to progressing. In this way the long-term continuous sustainable improvement process has become "cultural" throughout the supply chain supported shared objectives and a common approach. In the words of Steve Bounds (Burcas - General Manager): "Building and maintaining complementary relationships is one of the biggest challenges companies face today. He continued "Our longstanding success has been based on technical expertise and our willingness to innovate. We are prepared to go out and try new techniques, when perhaps others would shy away from technical difficulties or new processes - that's what separates Burcas from our competitors."
The affect on the bottom line has been dramatic. Mike Burrows (Burcas - MD) said: "The implementation of our SC21 campaign to date has helped BURCAS to secure over £1m of new orders from the aerospace industry alone. Building and maintaining complementary relationships is one of the biggest challenges companies face today."
To quote Mike Burrowa (MD): "With TEC's help Burcas and its supply chain are now able to provide our aerospace customers not only with a better service immediately, but with a commitment to ongoing improvement in the future."
SC21 Supply Chain Groups
Engaging with the SCG (supply chain group) is crucial to sustaining SC21-levels of delivery and quality performance for the end customer
On-site mentoring
In addition to the formal lean-six sigma training, on-site mentoring and coaching takes place to ensure support for each of the projects
Quantified improvements
The programme is focused on delivery and quality plus the DTI's 7QCD measures and utilizes Lean-Six Sigma improvement projects to create and sustain the gains