Achieving excellence through
accelerated learning
Achieving excellence through
accelerated learning
Aerovac Systems specialise in the sourcing, distribution and development of composite process materials & reusable vacuum bagging systems, and silicon rubber constructions for the aerospace, defence and wind industries.
Following on from the success of a DTi Supply Chain Programme hosted by GKN Kings Norton, Aerovac continued its company development in January 2008 by embarking on the GKN-sponsored SC21 Deployment Programme facilitated by TEC (SC21 Strategic Partner and Training Partner). TEC conducted the in-depth SC21 'diagnostics' culminating in the company's CSIP (Continuous Sustainable Improvement Plan) which provided an excellent 'company road map' for continuous improvement. This essential work was grant-subsidised by MAS Y&H.
The CSIP provided the focus for prioritized improvement projects were explicitally defined in Project Charters. All projects were undertaken using the DMAIC methodology. TEC's six sigma Black Belts provided the training and hands on project mentoring, giving the teams enormous enthusiasm, motivation and drive which was transferred throughout the departments as the projects progressed. To ensure support for all of the projects, champion training was given to senior management including discussions on how to define, evaluate and approve projects. Yellow belt training was provided in parallel at the shop-floor level to ensure support for the projects from a data capture and implementation perspective. In all six members of staff qualified as Green Belts. "The training provided was both comprehensive and excellent. The projects have played a large part in focusing on improvement activity but has also had an impact on cultural change and customer perceptions of Aerovac Systems Ltd. The work will form part of our ongoing improvement programme going forward and is core to maintaining the existing customer base and winning new business" said David Wiseman.
As a direct result of the six sigma-based programme, Aerovac have a better understanding of their process capability and the need to improve. They have gained project management skills, team-working and change management skills, and ultimately the confidence to measure and analyse a process in a proactive manner. "Excellent project, really helped to improve our processes through a structured approach. Good course materials very well presented" Andrew Dixon.
In parallel, Aerovac saw the need to upgrade their already stringent quality management system to encompass all aerospace and defence customer requirements and to lock-in our advancements in lean manufacturing and Six Sigma. Selecting the new Rev C revision of AS/EN9100 was a logical choice because it embraced both aviation and defence and is recognised by the global Primes and Tier-1 organizations.
Aerovac wanted to dispense with the traditional approach to quality management systems that relied on volumes of narrative procedures that had little or no practical use to support their modern and data-driven organization. Also the top management team wanted to be personally responsible for ensuring that product conformity and on-time delivery performance are measured and that appropriate action is taken if planned results are not, or will not be, achieved to support SC21. Working with TEC they therefore started from scratch and now have a visual and process-driven system that has been developed and documented with the full involvement of all concerned. They are already seeing dramatic improvements in ownership, compliance and performance overall and at the ‘process level’. Aerovac flew through the third-part assessment audit and attained AS/EN9100 certification in March 2010. What is more their system is fully compliant with the new Rev C edition of the standard and reflects the company's team-working and change management strategies.
Aerovac SC21 signatory
Aerovac are well underway with their SC21 delpoyment with TEC acting as their SC21 Training Provider. They are and targetting a Bronze Recognition Award by the end of this year.
CSIP deployment with 6-Sigma
Aerovac's CSIP provided the focus for prioritized improvement projects were undertaken as formal Six Sigma 'break-through' projects
Six Sigma Green Belts
Deploying the SC21 CSIP has led to the training and qualification of one Six Sigma Green Black Belt and six Six Sigma Green Belts. Senior managers received Six Sigma Champion mentoring