RAIL PROJECTS
LPMM has over 20 years of experience in supporting the railway industry globally. Our team have implemented significant improvements and cost savings across many railways. We pride ourselves in "delivering beyond the impossible"
Train Refurbishment Improvement
The Problem
Our client, a tier 1 supplier to London Underground was tasked with refurbishing a fleet of rolling stock.
The client was having difficulties meeting the production times and delivering a quality product. LPMM was engaged to review the production processes and design a solution that would meet the cycle time, improve the quality output and deliver significant cost savings.
The Solution
LPMM reviewed the current processes and conducted a 'process mapping' exercise to identify bottlenecks, unnecessary overwork and efficient work methods. A "right-first-time" quality system was designed and implemented that enabled quick and effective feedback to the production lines when any quality defect was identified. This allowed for strong containment measures to be carried out until root cause and countermeasure activities could be completed.
LPMM also introduced daily visualisation meetings where everyone from the shop floor to the board understood their planned Vs actual output. This allowed instant recovery plans to be developed.
Results
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Throughput time reduced from 12 days to 8 days.
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First-time quality improved by 60%
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Culture change of continuous improvement observed across the business
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A return on investment of over 10:1 recorded
Performance Improvement
The Problem
Our client was responsible for running Melbourne's Metro network which was underperforming and not meeting its contractual requirements, our client also wanted to introduce a continuous improvement culture throughout the business.
LPMM was engaged, because of its reputation of delivering results in a highly unionised work environment and its expertise in network improvement processes
The Solution
LPMM first analysed the business performance to understand key performance improvement areas and clear KPI's that needed to be measured and delivered. These measures were visualised and monitored daily by each department. Through Visualisation each department was empowered to challenge the results, review improvement actions and measure results.
The visualisation process was deployed from board level to each area across the organisation. Very quickly the business could see which area needed support and what actions needed to be implemented
Results
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Performance improved from an average of 86% (contractual target 90%) to an average of 92% within a year.
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Visualisation and continuous improvement adopted across an unionised workforce.
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Safety and bottom-line results exceeded our client's expectations