A Staffordshire-based powder coating manufacturer is celebrating the first phase of a major transformation project that has boosted efficiency, productivity and staff engagement.
Thermaset, in collaboration with lean manufacturing consultancy PJR Lean Associates, embarked on a continuous improvement initiative nearly a year ago. The project, aimed at embedding lean principles throughout the organisation, has already delivered significant results.
The initiative was led by Peter Rogers from Leek-based PJR Lean Associates, who worked with Claire Jennens at Thermaset to provide consultancy services focused on developing middle managers and engaging shop floor staff. While Tamworth-based Thermaset had previously implemented lean principles at a senior level, Claire was keen to ensure that these practices became embedded across the company, particularly among long-serving employees.
As a result, productivity and efficiency have increased, employee retention has strengthened and future leaders within the company have been identified. Staff are now actively measuring their own performance, working towards green performance indicators and taking greater ownership of their roles.
The team, led by Peter, revamped the management information system, introducing an hourly dashboard with key performance indicators (KPIs). This real-time data allows staff to make immediate adjustments to improve productivity, providing management with detailed insights and helping to break down barriers to change.
Production efficiency rose from 71.7 per cent in September to 92.63 per cent in February, an improvement of 29.19 per cent or 20.93 percentage points.
Claire said: “Thanks to Peter, we are now more aware of what we are capable of. Using data and a more empowered team, we can take on more work, have a better profit margin due to efficiencies and have future-proofed the business.
“There is a buzz about the place, and we have linked our innovative laboratory team to the manufacturing team for a collective approach. We have a much more confident team of staff, ready to problem-solve.
“Peter came in and from day one, he engaged with all staff, coaching them rather than coercing them. He has allowed me and the leadership team to focus on strategy while letting the shop floor excel at what they do best.”
Peter added: “On arriving at Thermaset, I found a wonderful, family-owned business with a great leadership team open to change and passionate about their people. Claire never stood in the way of new ideas and was prepared to have difficult conversations when it came to change management.
“We have a plan going forward, building on the initial success that has been achieved with the team at Thermaset, and I am confident that further strategic objectives with the senior team, local improvements with the shop floor and laboratory teams will deliver sustained people and process improvement throughout the plant.”
