Halewood's journey of excellence

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Manufacturing News, Source : TheManufacturer.com
Published : 22 Mar 2007 16:29
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Manufacturers learn about the cultue change that has transformed Halewood into Ford's best manufacturing site.

The Manufacturing Alliance got together at the Jaguar Land Rover on Merseyside in March, to learn about the incredible lean journey undertaken at Ford’s Halewood plant. Thomas Klein, operations director at Jaguar Land Rover Halewood, gave a step by step analysis of how the plant had improved in just ten years, from being Ford’s worst manufacturing site to being acknowledged as its best for three successive years.

Ten years ago, the decision was taken to improve or die, he explained, and the transformation process began. The plant was refurbished to migrate from high volume production of the Ford Escort, to quality production of the Jaguar X Type. Robust operating processes and continuous improvement schemes were introduced, and a complete culture change undertaken. “Management needed to know that it had to change,” Klein said. Management underwent four days of training which was then cascaded down through all levels of the workforce. Now, “the most important guys in the plant are the ones on the shop floor. All others are there to support them.” The programme of change took two years, and one of the most powerful management tools, he reckons, is to go onto the shopfloor and do the ‘waste walk’, asking ‘is there anything we can do to support you?’ None of this change would have been possible without the involvement of the trade unions, he added.

The plant now produces the Jaguar X Type and the newly launched Freelander 2. Both models are built along the same production line, requiring flexibility from the workforce and even greater levels of sequencing from the suppliers. The meeting was told how the cockpits, bumpers and seats were supplied in sequence on a just-in-time basis from the adjacent supplier park. Not only that, but the majority of parts were sourced from the UK, with Germany as the second largest supplier.

Dr Nick Barter, programme director for the SMMT’s Foresight Vehicle Programme was asked to share his vision for what the UK automotive industry would look like by 2020. He began by describing its current state: world-wide overcapacity, high labour costs, and a stock market that takes only a short term view. Then he looked at the drivers for change: the focus on innovation, the influence of climate change and the need for improvements in efficiency and skills. What does the sector needed to do for survival, he asked. Finally, he presented his vision for 2020: we will be successful as world class high tech manufacturers with a flourishing low carbon industry, and science and engineering will be high status career choices. The definition of manufacturing will be broader to include the industries that service the sector, and society will have a local focus, with shopping, work and leisure just a short distance from home.

Julian Turner, managing director of Westfield Sports Cars then described how a small manufacturer unable to invest in high powered IT and robotics can cut waste, improve quality and efficiency through engagement of the workforce. The company has been empowering employees, who are given start to finish involvement in the product, and recognition of good work. “This is the most committed team I’ve ever worked with in my life,” he said. Many of the workforce have been with the company throughout its 25 year lifespan. Although employing just 47 staff, the company has managed a saving of £400 a week on ideas from the shopfloor.

The meeting was hosted by Clive Dopson, previously managing director of Lotus Cars and now manufacturing and engineering consultant, who led the ensuing discussion on the future of auto manufacturing in the UK, bringing David Dancaster, group finance director of automotive component maker Caparo onto the panel to join Thomas Klein, Dr Barter and Julian Turner. Delegates were then treated to a comprehensive site visit of the Halewood plant.

The event was sponsored by Accelerate, EDF Energy, MAS, SAS and Semta.