Tufnol Composites says it is embarking on a Lean training initiative in a bid to expand the business’ manufacturing capabilities and up-skill its workforce.
The Birmingham based manufacturer, which has been operating from its headquarters in Perry Barr since 1929, has enlisted West Midlands based Lean training provider, Lean Education And Development Ltd (LEAD Ltd), to work with teams of employees on projects tailored to their area.
Roy Thomason, Tufnol’s managing director, explained: “Currently we’re running four projects, with one of them, for example, focusing on a total re-organisation of one of our machine shops. We’re engaging all employees working within that area in the project, which will enable us to introduce new processes, effectively bringing in-house some work that we have previously had to sub-contract. This will mean that not only are we extending our capabilities, but making significant cost-savings in the process. “Essentially, we’re instigating a culture of continuous improvement which can understandably lead to a little reluctance at first, especially among some of our longer serving employees. However, once they took ownership of the process, we immediately began to see benefits in terms of improved organisation and visual management. “The four current projects will run over the course of a year and involve 50% of our workforce who will each work towards gaining a total of six qualifications including a diploma in Business Improvement Techniques. Assuming the projects continue to be successful, we then plan to engage the remainder of our employees.” LEAD has been successfully delivering Lean training projects to a growing number of large manufacturing businesses since the company was co-founded five years ago. Max Jones, business development director and one of the five co-founding directors of the company, said: “Tufnol, like many established manufacturers in the UK, already had a way of operating that worked for them. But there is always room for improvement. “Tufnol is pioneering a supply chain improvement initiative led by GKN Aerospace, who already understands the benefits of our training in terms of both the business and each of its employees, who are obviously the key to any company’s success. “Our training projects encourage participation and input from all employees, so they feel fully involved and important to the business. Following completion of the project, each employee receives their six qualifications – all of which are recognised by awarding bodies. By this time the workforce should be running a more efficient and less wasteful operation, resulting in increased productivity and reduced costs.” LEAD was introduced to Tufnol by GKN Aerospace which is promoting the deployment of Lean in its key suppliers. GKN Aerospace Europe’s head of supplier development, Tony Richards said: “By embracing this initiative Tufnol are demonstrating their commitment to Continuous Improvement and the GKN Supplier Development Programme. This identifies Tufnol as a supplier that GKN will want to work with on a long-term basis to our mutual benefit.” www.tufnol.com
