Continuous Process Improvement
Prepare Culture for IS09001: Certification, Business Process Audit, Recommendations
About The Client
A manufacturer of pumps used for pressure testing in the oil and gas industry.
Project Overview
- Business process audit checks for compliance on economy, efficiency and effectiveness of current state with focus on quality and safety of manufacturing and repair of pumps
Challenges
- 3 shift operation running skeleton crews
- Oil and Gas industry was experiencing an economic downturn
- Employee downsizing resulted in cross training and shorter hours
- Upcoming ISO audit
- Employees were afraid of losing their jobs
Solution
- Identified gaps in current state in comparison to ISO standards
- Updated SOPs and administered refresher training
- Performed safety tool kit talks beginning each shift
- Provided C-IQ coaching
- Implemented change management communication plan
- Updated PPE kits
- Reduced base models from 13 to 4 and adjust build kits
Business Impact
- The company was ISO certified
- Identified efficiencies were adopted with a projection of 25% improvement in manufacturing
- Manufacturing operations scheduled to locate into one facility
- Fear was being replaced with trust due to tools being utilized for transparency
