PZ CUSSONS

Maximum delegates:25

Lean knowledge required:intermediate/advanced

Key Facts:

• Number of employees at site: 120
• Unionised workforce
• 2005 Award winner for Commitment to Developing People
• The Manufacturing Institute's Manufacturer of the Year 2006 Award
• Operates six-day week, four crews per day

Issues to be discussed:

• Business support for innovation and continuous improvement
• Workplace organisation using 5S
• People development
• Engaging in total production maintenance

SIEMENS

Maximum delegates:30

Lean knowledge required:intermediate/advanced

Key Facts:

• Number of employees at site: 480
• Unionised workforce
• 2005 Award winner for Commitment to Developing People
• The Manufacturing Institute Manufacturer of the Year 2006
• Operates six day week, four crews per day

Issues to be discussed:

• General factory issues
• Total quality management
• Continuous Improvement programme
• Chance to meet team leaders

JAGUAR LAND ROVER

Maximum delegates:40

Lean knowledge required:begineer/intermediate

Key Facts:

• Production site for the all-new Land Rover Freelander 2 and X-TYPE model
• Halewood employs 2,500 people

Issues to be discussed:

• Tour across entire plant
• Visit to Premier Automotive Group Lean Learning Academy

HJ BERRY & SONS LTD

Maximum delegates:12

Lean knowledge required:begineer/intermediate

Brief history:

HJ Berry started its lean journey 18 months ago with a diagnostic visit by Julian Winn where various opportunities were highlighted and an implementation programme was agreed. Since starting we have reduced our stocks of raw materials, redesigned some of our production areas, implemented ISO 9001, implemented 5S in some production areas and offices, the list is endless. During the visit the delegate will see a production facility part way through the Lean transformation and hear fist hand of the problems that have been overcome with cultural, logistical and financial constraints and how a future state map has helped to develop strategic plans to move the business forward in all areas……

Key Facts:

• Number of employees at site: 86
• Family-owned business for the last 160 years (oldest furniture manufacturer in the country)
• All products are manufactured on site with no imported goods
• All raw materials are from renewable resources
• Probably the ‘greenest’ manufacturer in the UK

Issues to be discussed:

• Workplace culture
• The benefits of using VSM to develop a structured action plan
• 5S in factory and shopfloor environments
• The lean transformation and plans for the future
• Factory layout change

APPH

Maximum delegates:24

Lean knowledge required: intermediate

Key Facts:

• Number of employees at site: 87
• The site consists of an Assembly shop working a day shift and a Metal Finishing shop working a 3-shift pattern.
• The Metal Finishing carries out Nickel, Chrome and Cadmium electro-plating, NDT and paint.

Issues to be discussed:

• 5’s, in both the manufacturing and office areas.
• Visual Controls.
• Standardised Workstations, in both the manufacturing and office areas.
• Shadow Boards.
• Pull System for Sub-assemblies.
• Managing a ‘Bottleneck’ process.
• TPM system.

BRAINBOXES LTD

Maximum delegates:12

Lean knowledge required: intermediate/advanced

Key Facts:

• Number of employees at site: 50
• Established in 1984
• The company's product range includes PC add-on cards & software drivers
• 30% of total expenditure spent on research and development.
• All products are manufactured on site in Liverpool.

Issues to be discussed:

• A 20 minute honest look at Brainboxes’ Lean Journey so far.
• Questions and discussion.
• A 20 minute walk down the ’60 second’ production line illustrating improvement areas.

FULLCOLOUR.COM

Maximum delegates:10

Lean knowledge required: intermediate/advanced

Key Facts:

• Number of employees at site: 53
Family owned business established in 1993 Invests in latest innovation and technology Develops its people

Issues to be discussed:

• The benefits of using VSM and 20 keys to develop a structured action plan for improvement
• The lean transformation and ongoing plans for the future
• 5S in factory and office environments
• Factory layout change
• Measure for performance
• Importance of work group activity’s and follow through of actions

GRESHAM OFFICE FURNITURE

Maximum delegates:15

Lean knowledge required: Beginner

Key Facts:

• Number of employees at site: 350
• Our current turnover is £20m
• The company is privately owned and was established 30 years ago
• Gresham has always had a good reputation in the industry for being customer focused
• We specialise in the design and manufacture of office and leisure furniture
• We have our own fleet of vehicles that deliver nationwide
• We now have a recognised continuous improvement culture throughout the factory

Issues to be discussed:

• Communicating what our customers value throughout the business
• Waste elimination
• 5S implementation
• Continuous Improvement Teams
• Recent improvement projects
• Lessons learned during implementation

JAMES WALKER & CO LTD

Maximum delegates: 30

Lean knowledge required: intermediate

Key Facts:

• Number of employees at site: 60
• Structured around Industries
• Technical advice available
• Recent Visual Management Implemented as part of the ‘Lean’ process
• Approx 3,500 orders and 2,000 enquiries processed per month

Issues to be discussed:

• Removal of waste from processes
• Restructuring of organisation based around customer typologies
• Consolidation & relocation of teams
• Identification of skills required
• Measures of performance and focus for different customers
• Cultural Issues
• Standards for performance

RITHERDON

Maximum delegates: 16

Lean knowledge required: Beginner

Key Facts:

• Number of employees at site: 35
• Ritherdon and Company was founded over 100 years ago
• UK’s largest supplier of steel domestic meter boxes and meter box refurbishment units

Issues to be discussed:

• Improving factory layout
• 5S and visual management
• Managing culture change
• Team working and employee empowerment

SWS

Maximum delegates: 15

Lean knowledge required: Beginner/Intermediate

Key Facts:

• Number of employees at site: 164
• Manufacturers of security products and garage doors
• All products at SWS UK are bespoke
• 2 years into the lean process

Issues to be discussed:

• Tour across areas at different stages of Lean
• Lean productivity implications
• Problem Solving

BAE SYSTEMS

Maximum delegates: 30

Lean knowledge required: Beginner/Intermediate

Key Facts:

• Number of employees at site: 3,800
• Visit production facilities of F-35 Joint Strike Fighter & Eurofighter
• People development for lean processes

Issues to be discussed:

• Developing the behaviour for lean improvements
• Culture and change management
• Continuous Improvement programme

NOTE: Due to high security levels at Samlesbury all delegate registrations for this visit are required by Tuesday, 9th October 2007. Delegates may be asked to provide information including passport details. Some delegates may be precluded from participating and will be notified within three weeks of applying

BENTLEY

Maximum delegates: 12

Lean knowledge required: Advanced/Intermediate

Key Facts:

• Number of employees at site: 4,000
• Production of all Bentley models
• Format based on ‘Customer Tour’

Issues to be discussed:

• Showroom
• Main build hall & production Line
• Wood shop

TYCO FIRE PRODUCTS

Maximum delegates: 25

Lean knowledge required:Intermediate

Brief history:

Tyco Fire Products Manufacturing, commenced their lean journey 18 months ago. Their main focus in the early stages has been reversing a declining shop-floor culture to an embracing lean culture. Initially by re-structuring the shop-floor teams, enforcing a zero tolerance process discipline and ensuring employee accountability. This transformation then progressed to implementing Visual Management KPI reporting, displaying all metrics with escalations in the work areas. 5’s tools were then installed in all areas with the teams completing their own layout and make over improvements. New investment in machines and equipment provided the impetus for Lean Cellular Manufacturing developments Since starting, we can celebrate many improvements including improvements in:- H&S, absenteeism, productivity efficiencies, On-Time delivery, training and development, Layout savings, Scrap, etc During the visit the delegates will see a production facility part way through the Lean transformation and hear fist hand of the problems that have been overcome with cultural, logistical and financial constraints and how the site plans their future Continuous Improvements efforts.

Key Facts:

• There are 140 employees at this site, producing a high variety of sprinkler systems
• Stockport facility is the European Headquarters for Sprinkler Manufacturing
• The Lean Transformation has been implemented in-house
• In collaboration with the local Union and FE College an onsite Learning Resource Centre has been created

Issues to be discussed:

• Lean Transformation
• Workplace Culture and Change Management
• Visual Management & 5S
• Cellular Manufacturing
• Future Improvement Initiatives

LINPAC PLASTICS

Maximum delegates: 18

Lean knowledge required:Advanced

Key Facts:

• Number of employees at site: 137
• The site opened in 1998 and has employed continuous improvement techniques throughout that time.
• All materials used in the product manufacture are internally recycled.
• Problem solving methods are embedded.
• Labour and cost efficiencies are in the Industry Sector top quartile.
• Energy Efficiency is continually improving.

Issues to be discussed:

• Autonomous teams.
• 5S in practice.
• Asset Care (TPM).
• Cell working.
• LPOS.
• Accelerated change.

VAUXHALL MOTORS LTD

Maximum delegates: 16

Lean knowledge required:Advanced

Key Facts:

• 2187 employees consisting of 236 staff and 1951 hourly
• Capability of 43 jobs per hour
• Capacity of 190,000 per year on 3 shifts
• Total production of over 400,000 vehicles
• Produce Astra 5 door hatch and Astravan

Issues to be discussed:

• General Motors overview
• Background to the plant
• Recent Achievements