A remarkable lean journey – Jaguar Land Rover style

Manufacturing News, Source : The Manufacturer
Published : 10 Apr 2007 15:17
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ALLIANCE: High-powered debate on the future of automotive manufacturing in the UK

At a Manufacturing Alliance meeting at the Jaguar Land Rover on Merseyside in March, manufacturers learned about the incredible lean journey undertaken at Ford’s Halewood plant. Thomas Klein, operations director at 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 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. Now, said Klein, “the most important guys in the plant are the ones on the shop floor. All others are there to support them.” The plant now produces the Jaguar X Type and the newly launched Freelander 2, and both models are built along the same production line.

Dr Nick Barter, programme director for the SMMT’s Foresight Vehicle Programme was asked to share his vision of UK automotive industry in 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. Finally, he presented his vision for 2020: successful as world class high tech manufacturing with a flourishing low carbon industry, and science and engineering as high status career choices.

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 and improve quality and efficiency through engagement of the workforce. Employees 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. Although employing just 47 staff, the company has achieved a saving of £400 a week on ideas generated 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 to see lean in action.

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

 

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