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Kepner Tregoe Hi Performance Manufacturing Alex Diong
Outline of Presentation ,[object Object],[object Object],[object Object],[object Object],[object Object]
Who are Kepner – Tregoe? ,[object Object],[object Object],[object Object],[object Object],[object Object]
What does Kepner Tregoe do? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Training Short – Term Consulting HPM  Consulting
HPM Clients BHP Steel One Steel SSM Boral Masonry Boral Bricks, GA Boral Bricks, AL Aristocrat Aristocrat, NV JNJ Consumer, NJ Kimberly Clark, WA North America Moen, OH Amcor Aerosols CSR Sugar Europe CSR Monier Wunderlich One Steel Pipe & Tube Visy Pulp & Paper Cement Australia Corning CSR Insulation China CSR Insulation Malaysia BlueScope Steel Thai Corning  Shanghai UK Coal LaFarge Dieconnex Bona Floors Burgmann Simplot Rio Tinto One Steel Rod & Bar APAC Amcor Fibre  Packaging Mitsu Metals
What is Hi-Performance Manufacturing? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Achieving HPM ,[object Object]
Achieving HPM Structural Costs “ Doing the Right Things” Products we offer Customers we serve Supply Chain  Partners Operational Costs “ Doing Things Right”   Safety & Environment Prime First Time Production Rate Equipment Reliability Process Control 100% On-Time Delivery Structural Costs Operational Costs
Inputs to Hi Performance Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Improvement Initiatives ,[object Object],[object Object],[object Object],[object Object]
Analysis – The Challenges ,[object Object],[object Object],[object Object],[object Object],[object Object],Suggestion Box Resource Constrained New View /  Paradigm Shift Management Input Level Payback level $ Step Change Zone Efforts – Diagnostics – Systems - Resources   Incremental Improvement Zone
Analysis – Recommended Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Analysis – Recommended Approach (cont.) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Analysis – Self Assessment
Analysis – Self Assessment
Analysis – Self   Assessment Volume-Margin matrix assist in assigning specific improvement areas Margins Low High Volume High Low Margin Improvement Growth Substitution, Outsourcing, Elimination Protection Operational Marketing Marketing / Operations Operations / Marketing Responsibility Focus
Analysis – Self   Assessment
Project Identification – Recommended Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Documented Savings Sheet ,[object Object],[object Object],[object Object],[object Object],[object Object]
Prioritisation Matrix ,[object Object],[object Object],[object Object],[object Object],[object Object]
Implementation – Recommended  Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Sustainability – Recommended  Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Fb S P R C + Situation How clear are the performance expectations and how well are  they understood? How clear is the signal to perform? How well does the work  environment support expected performance? Consequences How well do the  Consequences encourage expected performance? Response What is the observed  performance? How does it compare  with expectations? Performer How capable is the Performer to meet  the performance expectations? The Performance System Feedback How appropriate is the  Feedback and how well is  it used to influence performance?
Thank You
Client Results
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Steel Manufacturer
Throughput Analysis (Before)
Throughput Analysis (After)
Yield Improvement
Throughput Increase
KT Rational Processes
Problem Solving & Decision Making
Project Management

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Hi Performance Manufacturing

  • 1. Kepner Tregoe Hi Performance Manufacturing Alex Diong
  • 2.
  • 3.
  • 4.
  • 5. HPM Clients BHP Steel One Steel SSM Boral Masonry Boral Bricks, GA Boral Bricks, AL Aristocrat Aristocrat, NV JNJ Consumer, NJ Kimberly Clark, WA North America Moen, OH Amcor Aerosols CSR Sugar Europe CSR Monier Wunderlich One Steel Pipe & Tube Visy Pulp & Paper Cement Australia Corning CSR Insulation China CSR Insulation Malaysia BlueScope Steel Thai Corning Shanghai UK Coal LaFarge Dieconnex Bona Floors Burgmann Simplot Rio Tinto One Steel Rod & Bar APAC Amcor Fibre Packaging Mitsu Metals
  • 6.
  • 7.
  • 8. Achieving HPM Structural Costs “ Doing the Right Things” Products we offer Customers we serve Supply Chain Partners Operational Costs “ Doing Things Right” Safety & Environment Prime First Time Production Rate Equipment Reliability Process Control 100% On-Time Delivery Structural Costs Operational Costs
  • 9.
  • 10.
  • 11.
  • 12.
  • 13.
  • 14. Analysis – Self Assessment
  • 15. Analysis – Self Assessment
  • 16. Analysis – Self Assessment Volume-Margin matrix assist in assigning specific improvement areas Margins Low High Volume High Low Margin Improvement Growth Substitution, Outsourcing, Elimination Protection Operational Marketing Marketing / Operations Operations / Marketing Responsibility Focus
  • 17. Analysis – Self Assessment
  • 18.
  • 19.
  • 20.
  • 21.
  • 22.
  • 23. Fb S P R C + Situation How clear are the performance expectations and how well are they understood? How clear is the signal to perform? How well does the work environment support expected performance? Consequences How well do the Consequences encourage expected performance? Response What is the observed performance? How does it compare with expectations? Performer How capable is the Performer to meet the performance expectations? The Performance System Feedback How appropriate is the Feedback and how well is it used to influence performance?
  • 26.
  • 32. Problem Solving & Decision Making