Productivity case studies
NOCN works with employers from micro businesses to large corporates on productivity improvement, offering a complete learner package.
Case Study: Trailblazers in Productivity, UK
A.E.Rodda’s & Son, ATN Teaching & Consultancy Services Ltd and NOCN recently celebrated the successful completion, by 11 Rodda’s staff, of the NOCN Level 4 Certificate in The Management of Productivity.
Darren Howells, NOCN Head of UK Business Development, described Rodda’s as ‘trailblazers’ of productivity. He further applauded the Rodda’s cohort in being the first UK recipients of the Level 4 Certificate in The Management of Productivity and Rodda’s for supporting and promoting the development of its staff. For any programme to even have a chance of success, it needs commitment, competence and consistency from all involved.
The qualification itself is not the end of the story, as the drive to improve Productivity is a continuous one.
Mark Dudderidge, Rodda’s Director and Chair of the Cornwall and IoS LEP recognise that improvements in productivity don’t ’just happen’! Improvements require a change in culture, investment, time, developing knowledge, skills and ultimately a change in behaviour. Standard approaches involve the education and upskilling of staff by the acquisition of knowledge and testing that knowledge through academic means. However, the ATN approach and the nature of the NOCN Management of Productivity suite is such that the qualification is achieved through workshops, 1-1 support, guided tasks at the employee’s place of work that provides multiple opportunities for the theory to be put into practice.
Firstly, during the consultation phase of the programme, Rodda’s identified several key areas for development within their organisation – Critical Success Factors. Sean Boyle, Director of Training Development at ATN then created a tailored programme, which enables the qualification needs to be met, but more importantly provided a framework for productivity improvement projects to be successfully undertaken. Projects that produced tangible results.
For Rodda’s, The Management of Productivity qualification involved Continuous Improvement, 5S, Workforce Planning and Performance Measurement and Management modules were undertaken. These fed into multiple projects such as, material waste reduction including measurement, source and actions to prevent; waste management including relevance, accuracy and visibility of all performance data; Staff skills development to produce improved flexible working and therefore productivity; process and procedure development; stock and inventory control including stock movement and storage; machine efficiencies, labour balancing and cost optimisation.
As well as identifying stock valued in the tens of thousands, savings have also been made by improving processes. One particular process now uses 80% less water, which for a company that on average used 2960 litres per day; over 1 million litres per year, is a significant saving. Rodda’s is now in a position to reduce this to approximately 620 litres per day. This also had the knock-on effect of reducing the power needed for the process, reduction in effluent, reduction in cycle times and labour required.
Projects also identified areas for improving machine availability through TPM application – reducing critical machine downtime. Training programs have been created, which have improved the knowledge and skills of staff and therefore provided opportunities for flexible working.
The application of 5S, in a number of areas, has identified multiple opportunities for reducing waste in terms of unneeded excess stock; unnecessary movements of products, materials and staff; productive time lost locating materials and products needed; improved stock control and rotation. The visibility and access to performance measures has allowed for greater ownership and opportunities to act.
Mark Dudderidge, Director at Rodda’s, The Creamery and Chair of the Cornwall and Isles of Scilly LEP.
“ATN’s hands-on, supportive and empathetic approach to training is beginning to empower more of our first line supervision to proactively manage their area’s and to make a real change to our operation. We now expect the pace and efficacy of the team to increase as they continue to build their confidence and knowledge of best practice. ATN’s blend of coaching, shop floor support and accessible classroom teaching is exactly the right approach for our organisation”.
Rodda’s and ATN Teaching & Consultancy are now looking forward to the second cohort, supporting them on their journey and ultimately improving productivity and practice at Rodda’s.
Sean Boyle, Director of Training Development.
“I’ve been delighted by the commitment shown by the first group and the collaborative approach that Rodda’s and I have fostered. I’m sure the confidence and ownership demonstrated by the first cohort will continue to blossom with the second Rodda’s cohort”.
Case study: Productivity & Employability Skills Course, Bangalore
This is a pilot course for 23 learners and is run in Bangalore, one of India’s largest cities. The course has been run at Seshadripuram College which is part of the Education Trust.
What we delivered
The course is four weeks long and uses an industry case study of a concrete block plant to help learners develop their employability skills with the context of an exercise to also see how productivity can improve. A local construction firm has allowed their block manufacturing plant to be used for the practical parts of the exercise.
Where we added value
Learners have found this interactive and practical way of learning very exciting. Below are some pictures of lecturers and the various ‘project teams’ who have competed against each other for the best ideas and presentation.
Case study: Norseland Ltd - Improving Productivity with NOCN
A global speciality cheese business with innovation at its heart, Norseland brings together Norwegian and British expertise in cheese production and manufacturing. Norseland has a range of award-winning sweet and savoury cheeses that are successful both in the UK and around the world. Taking centre stage from Norway is Jarlsberg®, admired by leading chefs worldwide, whilst brands from the UK include the ever popular Applewood® Cheese, Mexicana®, Ilchester® and Five Counties®.
Norseland worked with Devon-based training provider ATN Teaching & Consultancy Services Ltd to support a middle manager to undertake the NOCN Level 4 Management of Productivity Diploma.
Image of Przemyslaw Huber, Norseland LTDThe learner, Przemyslaw Huber, has undertaken the following units through a combination of e-learning (via moodle.nocn.org.uk), projects, assessments, professional discussions, and mentor support:
• Strategic Management
• Continuous Improvement
• 5S to Improve Productivity
• Organisational Development for Improved Productivity
• Workforce Planning to Improve Productivity
• Performance Measurement & Management
• Using Benchmarking to Improve Performance
• Risk and Issue Management
• Planning for Operational Change
Sean Boyle, Director of Training Development at ATN Teaching and Consultancy Services Ltd, said: “A smart and forward looking business looks at improving its productivity. Therefore, it comes as no surprise, that as a nation, productivity is a hot topic. NOCN’s suite of Managing Productivity qualifications in conjunction with ATN’s flexible learning approach, professionalism and passionate collaborative support has proven to be a winning formula for Norseland."
What we delivered
Up-skilling the future needs of any management team, is an essential step in developing a business. Norseland have embraced this and although the delegate undertaking the Diploma route, has found certain aspects of the qualification challenging, he has found the support given, the course materials - physical and online, and the variety of assessment approaches and outcomes has been most beneficial.
The challenge is to find a balance between the needs of the employer, the employee and the qualification itself validity. A collaborative approach between ATN and Norseland has ensured that these endeavors will have maximum impact on the learner, productivity improvements and complement Norseland’s forward looking succession planning strategy. A work based projects and assignments approach is enabling theory to be put into practice.
Chris Harrison, Learning & Development Advisor at Norseland, said: “The NOCN Management of Productivity Suite has enabled us to up-skill the future needs of our Management Team and it has already reaped rewards for the business; the project has enabled small changes that will have a big impact on productivity.”
The improvement has been seen in several areas. Not only has the learner benefited from becoming much more confident and capable in their role, but also their ability to work more independently and more efficiently by identifying and providing solutions to challenges and issues. This has benefited both his team and senior management. The Operations Manager has noted that he is no longer heavily relied upon for strategic support, which is saving duplication of effort and freeing up his time for higher level tasks, while those in his team are able to take on more responsibility and deliver better results. A greater understanding of the company’s vision and mission and the role of enhanced productivity in delivering it is now embedded into the day-to-day operations rather than just sitting with the ‘upper echelons’ of management. This ‘cascade effect’ will have a long-term impact on the business.
Where we added value
As a result of its success with Norseland, training provider ATN has now been asked by Roddas, a leading supplier of Cornish clotted cream, to take 11 of its area leaders through the NOCN Level 4 Certificate in The Management of Productivity. As with Norseland, a collaborative approach is being undertaken. This will involve four carefully selected core modules, delivered through workshops, on-site training, course materials, projects, assignments and mentor/coach visits, to ensure maximum gain.
Case Study: Productivity Improvement Programme in the Middle-East/Gulf
NOCN and training provider Jafcon’s Level 5 Productivity Improvement Practice suite of qualifications is designed for organisations in the Middle-East and Gulf in a wide range of sectors including aviation, banking and financial services, construction, education, logistics, manufacturing, Oil and Gas, and the public sector.
What we delivered
This suite of qualifications includes an Award, Certificate, and Diploma and is designed for managers, practitioners, supervisors, aspiring future managers and students in their final year. The qualifications enable learners to progress, gain knowledge and improve productivity at team, department, and strategic levels; driving business success and expansion. There is significant potential return on investment from cost savings and productivity gains through this training.
Where we added value
Companies that have completed the programme include:
• Bahrain Petroleum Company, which reported a $4 Million saving.
• Bahrain National Gas (Banagas), which identified savings of $5.08 Million and gathered detailed data on productivity levels across the business.
• Dubai World, which identified a number of projects and improvement opportunities.
• Bahrain Airport Services, which put 20 senior employees through the programme who are now potential future leaders of the organisation, leading to significant financial savings and return on investment.
• BMMI Group, which put 21 internal consultants through the programme and has seen a marked improvement in productivity.
“BMMI recommends the Productivity Improvement Practices (PIP) to other companies and especially to those companies who seek real and effective improvements of the company’s productivity and the uplifting of their employees.” Mr. Mohammed Turaif, Manager, HR Operations & Administration at BMMI Group.