 Derby-based Tex Industrial Plastics Limited (Tex IP) has over 180 employees and specialises in large, high-specification plastic injection moulding solutions.
Glyn Thomson, Tex IP’s Training Officer, describes the tough challenges facing his organisation, “like most injection moulders in the UK we are struggling with escalating costs and increasing competition from low-cost producers. We can only survive through utilising new technologies and increasing employee awareness & skills.”
In July 2007 Tex IP commenced phase one of a three-phase Business Improvement Techniques (BIT) NVQ level 2 training programme with Derby College. Fifty production staff completed the qualification early in 2008 and the company is now progressing through phase two for 45 non-production staff. Phase three will provide training for the remaining production staff.
David Clarke, Derby College’s on-site assessor, explains the training process, “We introduced the theory in team meetings, then facilitated sessions to analyse specific issues and develop solutions.”
Glyn adds, “each team focuses on a key area, customer account or business process issue. This approach gets departments working together for the benefit of the customer.”
David comments, “There are no formal examinations, it is a 100% competence-based assessment completed within teams in the workplace.”
Benefits and Outcomes
The first improvements were visible management changes in the workplace. Glyn says: “Housekeeping improved and we are now proud to show visitors areas behind machinery, and packaging, tool & equipment store areas”
“The main efficiency benefit from phase 1 has been workplace re-organisation e.g. to minimise delays in locating tools and components and reduce waiting times with KANBAN systems. Phase 2 has increased inter-department action to address efficiencies e.g. reviewing software systems to improve accuracy of information and rationalising packaging so reducing stock-takes by 30 minutes, saving 24 hours p.a.”
The programme has made a major impact on culture, Glyn adds: “since the training, employees take ownership of their areas and other teams are noticing the differences and asking questions. We have seen improved understanding and communication to jointly resolve issues.”
For more information contact:
Glyn Thomson, Tex Industrial Plastics Limited. glynt@texip.co.uk; or
David Clarke, Derby College: david.clarke@derby-college.ac.uk
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