Daz Owen from Paint Shop certainly has what it 'bakes' when it comes to ‘raising’ a good kaizen.
Daz’s simple yet effective idea to leave the Sealer Bake oven full at shift end - instead of previously leaving it empty - means we no longer have a 20-minute delay in production each morning- which was the time it took for the cars to arrive at each process.
Thanks to this recipe for success, we can now increase the volume of cars we put through the Sealer Bake oven, delivering an additional 65 units a week for our customers, as well as improving the quality of our processes - a great example of Refocus in action!
But why wasn’t this done before?
Daz, who has been named as our latest Kaizen of the Month winner, said: “Previously when we left cars in the oven at shift end, it had caused some water leaks. So essentially when the oven cools down in the evening and warms up in the morning, the sealer coat on the cars can become overbaked, and therefore crack.
“As a result, the process for as long as I’ve known it, was to clear all the cars from the oven at shift end, but this then caused a 20-minute gap in production each morning as the cars had to be cleared first.”
Not one to throw in the (tea) towel when faced with a challenge, Daz took it upon himself to see if there was another way of doing things… and there was.
Working with our suppliers, Henkel, in Germany, he discovered that the sealer material we now use on our vehicles has been upgraded and is robust enough to withstand the change in temperatures, meaning it wouldn’t crack if it was left in the oven overnight.
Daz and the team have now performed all essential post checks and since the new process has been implemented, there have been no water test fails when the cars arrive into Trim and Final.
Asked what inspired him to raise his Kaizen, he said: “I see the challenges our teams face every day getting cars forward and rather than accepting that this is only way to do things, there is always another solution - even a simple one. That’s what kaizen is all about.”
Dave Buxton, Maintenance Manager in Paint Shop, said: “As part of our new company purpose, we’ve recently rolled out our Creators’ Code, and the Customer Love mindset is integral to that. For me, that’s exactly what Daz has delivered here as it is all about the end customer.
“He has left no stone unturned, and was part of all the post checks, working alongside our suppliers to find a solution and challenge the norm. As a result, we now have the potential of delivering an extra 65 cars a week to our customers, that are of the highest quality.”
Making small continual improvements through raising a Kaizen is a key way that employees can play their part in Refocus - our day job in Manufacturing which is helping to transform the way we operate at Halewood to improve quality, sustainability, and the profitability of our vehicles.
Finding new ways to improve the quality of our processes is how we can play our part in Refocus transformation and ensure Halewood is in the strongest position to successfully embed the electric architectures earmarked for our plant as part of Reimagine.
Have you raised a Kaizen? Please share your experience with us by emailing: email@example.com