Data Analytics Deliver Major Business Improvements

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Latest company updates and industry news

Data Analytics Deliver Major Business Improvements

A customer story

Photography by www.davidcopeman.co.uk

Over the last few years we have been working closely with one of our key clients, Johnson Matthey Edinburgh (Macfarlan Smith) supporting implementation of their OpEx programme. Data Analytics and JMP has been a big part of this, helping them get real value and new insights from their process data.

Process engineers and scientists on site now routinely use data analytics and statistics to optimise their processes and increase yield. JMP helps them identify and resolve potential potential problems before product quality is compromised. The “visual” aspects of JMP allow easy communication and participation in the analysis and ensures everyone in the organisation is engaged and involved in problem solving.

Read more here about this fascinating customer story

As we’ve grown, we’ve got people who are more comfortable with JMP, and because of that, we’re finding more complex problems and building more and more advanced analyses (to tackle those problems). JMP changes the way you collect data, clean data, how you organize the basic analyses and how you put it into a format that tells a story.

David Payne, JM Edinburgh Site Director

Do you want to get more value from your business data?

Do you want to bring your data analysis to a whole new level?

    • Solve difficult real word problems
    • Bring data alive
    • Dramatically communicate findings
    • Make better decisions faster
    • Double productivity
    • Accelerate Improvement

You can read more customer stories here.
To find out more contact Andrew Ruddick on 07785 927144.

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Summer 2018 newsletter

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Latest company updates and industry news

Summer 2018 newsletter

I am finalising this newsletter the morning after England knocked out of the World Cup. I don’t really follow football (too much arrogance, money and arguing and cheating for my taste!) but like many others I engaged with the relative success of this young team, and much to admire about the Manager with his quietly thoughtful, nurturing and visionary approach – perhaps offering some leadership lessons for us all to learn!

Also really enjoying the unusually hot and sunny English summer – it may not suit everyone but I have to say it suits me! Lots of summer distractions (Wimbledon, record scores in the cricket, the Open coming up) and lots to enjoy at the moment…..including the progress and successes of many of our clients.

Further Client Success at CIA Awards

Many congratulations to Johnson Matthey who were crowned Company of The Year by the UK Chemical Industries Association at their 2018 annual awards ceremony on 14th June. Last year Johnson Matthey Edinburgh won the ABB Manufacturing and Resource Efficiency Award, based on their OpEx improvement work. This year they have gone one better!

We are very proud to have Johnson Matthey as one of our longstanding clients and wish them much more success in the future.

Autumn Networking Events

We are planning a couple of Networking events later in the year on the theme of “Continuous Improvement as a day to day task – and how to achieve this alongside delivering Business As Usual”.

This particular topic has generated a lot of interest – after all it’s a problem that every organisation struggles with – so this year we are planning two events – one in London and one in Edinburgh. Dates are still to be finalized but will be sometime in late September/October.

If you are interested in coming let us know by clicking on this link and also tell us whether you prefer London or Edinburgh as a venue.
We will keep you updated with more details over the next couple of months.

We are delighted to welcome Orietta as the newest member of the PICL family. She brings a wealth of experience to the team, and also a passion for the “people” side of continuous improvement with a particular interest in how to engage everyone in OpEx through their daily activities.

Orietta is a highly-motivated and pragmatic Operational Excellence professional with extensive experience working in the oil & gas, healthcare, transport, agribusiness and sugar refining sectors.

She is a proactive and inspirational leader with a successful track record in delivering cost reduction strategies.

She says;

“My most enjoyable times are working with people, be it from the shopfloor all the way up to senior management. I relish the opportunity to remind them how much they know and contribute to the business, and for them to see alternative ways of approaching problems they have tackled in the past with little success. It is at that moment – when the lightbulb literally comes on – that I get my utmost satisfaction. Your people are what makes your business a success, and being able to leverage their knowledge and passion in ways they have not seen possible until now is, to my mind, my biggest achievement”

You can contact Orietta via email or phone, + 44 (0) 7814 721 650.

Our Regular Webinar programme

Our free webinars continue to be enjoyed by many of our clients. If you haven’t participated yet, then have a look at the upcoming programme – you may find something that could be very helpful for you. We cover a wide range of topics of general interest to those involved in OpEx & CI programmes– the aim is to provide you with practical guidance and “tips and tricks” on different aspects of process improvement.

Dear Andrew, Thanks a lot for the webinar, it was very useful. It helped me to get a sense to where to focus my energy in our deployment, and why things work or don’t in our program.

Oliver Kozak

LinkedIn PICLub

Talking of sharing “tips and tricks”, you might want to join our LinkedIn Group – The Process Improvement Club.

This is a LinkedIn community of “Friends of Process Insight” and practitioners, with the emphasis on sharing best practices to maximise the impact of OpEx and Continuous Improvement. It’s a group within which you can raise questions, get answers and generally contribute.

Click here to find out more and request to join if you are interested.

Autumn Open Programme

Don’t forget our Open Programme in The Autumn. If you are interested in Green Belt or Black Belt Training, JMP Data Analytics, Design For Six Sigma or learning more about “Change Leadership” then we have a course for you!

Also our highly popular OpEx Deployment Master-class for those who want to learn how to maximise the impact of their Improvement Programme.

Over 85% of our delegates would highly recommend our training, so you can be very confident that you are in the best of hands.

Our training courses are fully accredited by BQF and lead to GB, BB or MBB accreditation.

For further details of our Open Programme click here, or give me (Andrew Ruddick) a call on 07785 927144.

Congratulations To All Our Recently Accredited 'Belts'

At Process Insight we believe very strongly in people development, skills transfer and capability building. Consequently we are particularly delighted to offer our congratulations to those we have recently coached & certified. Certification represents a very important milestone in an individual’s personal development and is a great demonstration of sustained leadership & business impact. If you would like to find out more about becoming accredited then give us a call on 07785 927144.

Black Belt certification

Antonio Lombardi - Beltrame
Nicolas Schneider - Beltrame
Guillaume Ostyn- Beltrame
Guillaume Gourdin - Beltrame
Ludovic Briclet - Beltrame
Clément Ricquiers - Beltrame
Jacky Dessaint - Beltrame
Stephen McNeal - Fuji Diosynth
Edoardo Corradin- Beltrame

Green Belt certification

Richard Gradwell - Victrex
Richard Jebb - Victrex
Audrey Lucatelli - Johnson Matthey Edinburgh
Craig Neary - Johnson Matthey Edinburgh
Alan Taylor - Johnson Matthey Edinburgh
Richard Jarrold - e2v
Kristian Hawkins - e2v
Lewis Tucker - e2v
James Clayton - e2v
Tom Christopher - e2v
Tom Clayton - e2v
Marco Pengo - Beltrame
Paolo Corengia - Beltrame
Andrea Gaspari - Beltrame
Mauro Soffia - Beltrame
Andrea Cocco - Beltrame
Nicola Albarese - Beltrame
Christoph Zeltner - Beltrame
Roland Hänni - Beltrame
Jennifer Engl - Beltrame
Jan Metzler - Beltrame
Florian Hofer - Beltrame
Serge Nussbaum - Beltrame
Matthias Zechner - Beltrame
Giovanni Izzi - Beltrame
Michael Odo Beltrame
Miroslav Sapina - Beltrame
Steve Stebler - Beltrame
Predrag Matijevic - Beltrame
Marco Sardi - Beltrame
Richard Whiteside - Victrex
Diana Wijngaarden - Victrex
Alicia Dunne - Victrex
Tony Pickford - Victrex
Gordon Mcdonogh - Victrex

Should you have any questions or require more information about any of the content in this newsletter please do get in touch with either myself or Andy and we can discuss the simple next steps. Alternatively give us a call on + 44 (0) 7785 927144.
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BQF Awards

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Latest company updates and industry news

BQF Awards

Congratulations!

Photography by www.davidcopeman.co.uk

We want to congratulate one of our key customers, Luca Bargioni, AFV Beltrame, who won the Business Improvement and Transformational Leader Award at the BQF Awards last night. We are excited to have been working with Luca throughout the last 10 years and to continue to be working with him, supporting his further development.

This award recognises an individual who has made an exceptional contribution and long-term positive impact through a career of transformation and continuous improvement. They are highly respected professionals continuously looking for new ways to innovate; responsible for leading people; developing tangible strategies and goals over a sustained period having an enduring impact.

I’m absolutely delighted and very proud to have won this award. I would like to thank my many colleagues and friends I have worked with over many years who have helped and supported me and who have achieved some great things for their businesses. I’d also like to thank Process Insight who have been with me at every step. It’s been a lot of fun and I know it will continue to be so!

Luca Bargioni, AFV Beltrame

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December 2017 newsletter

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December 2017 newsletter

Season’s Greetings From Us All at Process Insight

The year just seems to fly by, and Christmas is almost upon us once again – so firstly Seasonal Greetings to you all from Andy, Andrew, Michaela & Orietta. As ever we have enjoyed working with you in 2017. We hope you have a great festive season and enjoy well-earned time with your family & friends.

With everyone being very busy in the run up to the holidays we will make this newsletter pretty brief and mention just a few quick highlights from recent weeks.

Our Annual Master-classes Continue To Be A Great Success

In Nov we ran our Change Leadership Master- class. This was followed a few weeks later in early December with our Opex Leadership Master-class. The aim of these workshops is to bring our clients together to learn and share best practices around Change Leadership and the deployment of Lean Sigma. We get tremendous delegate feedback for both these events:

The more the time is going on, the more I appreciate the value of the Process Insight team.

Elena C OPEX Leader Steel Production (Italy)

Better than most training… informal but packed full of information..useful in all aspects of life not just change leadership.

Rachel H Continuous Improvement Manager Chemical Industry (UK)

Absolutely perfect!

Vianney P Lean Six Sigma Deployment Leader Pharmaceutical Industry (Germany)

Anyone involved in leading or participating in an improvement programme will find these workshops enormously helpful (and fun!). Let us know if you would like to attend next year.

2018 Open Programme

The schedule for our 2018 Open Training Programme is now available.
If you are looking for the highest quality Green Belt, Black Belt, and Master Black Belt training look no further – our courses get rave reviews and over 85% of delegates would highly recommend to others.
Click here for more details.

Congratulations To All Our Recently Accredited 'Belts'

At Process Insight we help organisations solve their business problems in a way that supports the personal development of the people involved. Consequently we are particularly delighted to offer our congratulations to those we have recently coached & certified. Certification represents a very important milestone and is a great demonstration of sustained leadership & business impact. If you would like to find out more about becoming accredited then give us a call.

Master Black Belt certification

Meran Crawford - Royal London
Michaela Mueller – Process Insight

Black Belt certification

Elena Campedelli - Beltrame
Emiliano Sulprizio- Beltrame
Daniele Radin - Beltrame
Luisa Lovato - Beltrame
Lidia Zantedeschi - Beltrame
Massimo Scionti - Bormioli
Stefano Crobeddu - Bormioli

Green Belt certification

Greta Piccolo - Beltrame
Claudio Olivero Pistoletto - Beltrame
Matteo Negrello - Beltrame
Simone Vasconetti - Beltrame
Nicola Veneri – Beltrame
Jerome Quiohilag – Johnson Matthey Edinburgh
Alisdair Page – Johnson Matthey Edinburgh

Should you have any questions or require more information about any of the content in this newsletter please do get in touch with either myself or Andy and we can discuss the simple next steps. Alternatively give us a call on + 44 (0) 7785 927144.
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Autumn 2017 newsletter

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Latest company updates and industry news

Autumn 2017 newsletter

Happy Halloween…

I hope you enjoy reading about what we and our clients have been up to over the last few months. Also at this time of year many of us start preparing our goals and plans for 2018. There are a few topics in the newsletter that may help.

Have you seen our new website?

Check out our new website! We decided it was time – after 8 years – to refresh our website design, to give it a new look and feel and to better represent our style and approach. Also to make it easier for people to access the information they are looking for. We are very excited about the result and hope you like it to. We would welcome your feedback.

RPA - Death-knell or Opportunity for Lean?

We were delighted to run one of our regular client networking events in October. Hosted by RBS in Edinburgh the topic was very topical – “RPA – Death-knell or Opportunity for Lean”. Stimulated by some great input from delegates around the table, and with participants from companies including RBS, Standard Life, Lloyds, Coca Cola, Royal London, FujiFilm, we had some very thought-provoking discussions. The output from the event is available to anyone who is interested so please contact me if you would like a copy.

By the way – for those that want the executive summary the conclusion was overwhelmingly “opportunity” but with some key risks to be managed.

"A fantastic RPA event this afternoon, hosted by Process Insight. Thanks Andy Liddle, Andrew Ruddick and everyone who presented. See you at the next one! "
Meran Crawford, CI Lead Royal London

If you would like to attend future PICL networking events the next one will be in the Spring of 2018 and further details will be provided in an upcoming e-mail.

OPEX Planning for the next year

At this time of year our thoughts are turning towards planning and budgeting for 2018. Also for thinking about the focus and direction of our improvement programmes over the next 12 months. We have a couple of tools that can help and which are free for you to download:
  • Our OpEx Assessment helps you quickly review your performance against a number of OpEx foundations and areas of best practice. A sequence of checklist questions enables you to rapidly evaluate how you are doing and identify any gaps that might need addressing in 2018. This assessment addresses the “what”.
  • Our Deployment Benchmarking tool is based on 8 critical success factors for delivering value from your programmes. Whether you have a mature programme, or are just taking your first steps it is always valuable to know how you stack up versus best practice – and it may well steer you to better focus your improvement activities. This assessment addresses the “how”.
“The Process Insight Opex Assessment & “size of the prize” analysis has been enormously helpful in shaping the next phase of our Continuous Improvement Programme, and driving us towards high impact projects”
Liam Mills, Head of Continuous Improvement, Johnson Matthey

If you are interested in either tool please contact me.
 
Also you might be thinking about MBB certification as one of your personal goals for 2018 – if so we can help you do a quick gap analysis and identify a clear action plan to achieve this goal

Team news

Michaela has been very busy since joining us 12 months ago – time flies! A native German speaker, Michaela has been working a lot with Aenova, a German pharma company.
Supporting them in the delivery of a company-wide, multi–site OpEx deployment Michaela is probably spending more time in German airports than is good for her!  However her efforts are being very well received…

Fur mich war der Kurs (von Process Insight) ein voller Erfolg da ich meine Erwartungen und Ziele mit vollster Zufriedenheit erreicht habe. Ausserdem kann ich die Methoden und das Erlernte nicht nur geschäftlich einsetzen, sonder auch anderweitig nutzen.

Fabian G Supply Chain Manager

In addition to consulting and training in Lean Sigma tools, methods and deployment Michaela has particular interest in the “softer” aspects of continuous improvement. She has worked with several clients specifically with their Leadership teams to support more effective executive team-work and to provide “one-on –one” executive coaching .

Orietta Fiorroni joined us in April of this year. Orietta is a native Italian speaker and also has excellent French (further burnishing our pan European credentials!)  She brings with her 20 years of experience leading and supporting transformational change in organisations in the Oil & Gas, Agribusiness, Healthcare, Chemical Manufacturing and Sugar Refining businesses. She is a Lean Six Sigma Black Belt, a Siemens trained PACT (Project Acceleration through Coaching and Training) coach and a PRINCE2 Practitioner.

Orietta’s main interest is in leveraging the “people “side of an organization to achieve Operational Excellence. She is an executive coach, has designed and delivered a number of training programmes, and deployed LSS in various organisations. She believes in engaging and involving individuals from all ‘tiers’ in an organisation, simplifying the LSS language so it is accessible to all, and generally bringing Continuous Improvement from what is seen as a ‘function’ to the heart of the business. A particular focus area for Orietta is what she calls “performance management” – a blend of Visual management, Tier Management and Leader Standard Work which engages everyone in OpEx through their daily activities. 

Congratulations To All Our Recently Accredited 'Belts'

At Process Insight we believe very strongly in people development, skills transfer and capability building. Consequently we are particularly delighted to offer our congratulations to those we have recently coached & certified. Certification represents a very important milestone in an individual’s personal development and is a great demonstration of sustained leadership & business impact. If you would like to find out more about becoming accredited then give us a call.

Master Black Belt certification

Kit Erlebach-  FujiDiosynth Biotechnologies

Black Belt certification

Francesco Cavanna  - Bormioli Rocco
Alfonso Sciarrotta – Bormioli Rocco
Miguel Pinafiel – Bormioli Rocco
Andrew Scott – Standard Life

Green Belt certification

Vicky Mendoza – Johnson
MattheyAlison Lake – Johnson Matthey

Should you have any questions or require more information about any of the content in this newsletter please do get in touch with either myself or Andy and we can discuss the simple next steps. Alternatively give us a call on + 44 (0) 7785 927144.
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White Paper – Curing The Innovation ‘Growing Pain’

Case studies

See how we have helped clients across many sectors solve their business problems and deliver tangible benefits

White Paper – Curing The Innovation ‘Growing Pain’

In this article we focus on the innovation/NPD process and discuss how lean thinking can be used to simplify the process, accelerate time to market and drive increased profitability.

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White Paper – Successfully Navigating Business Growing Pains

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White Paper – Successfully Navigating Business Growing Pains

In this white paper we share our process improvement methods for successfully navigating business growing pains.

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White Paper – Achieving Operational Excellence in Pharma & Biotech

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White Paper – Achieving Operational Excellence in Pharma & Biotech

In this white paper we share our learning from working with several pharma and biotech companies in order to illustrate the best approach OPEX and continuous improvement in their highly regulated environment.

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Summer 2017 newsletter

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Latest company updates and industry news

Summer 2017 newsletter

It’s That Time of Year Again…

As we are all basking in a Summer Heatwave in the UK with hose pipe bans impending (at least at the time of writing in mid June), it is that time of year again for one of our regular newsletters. I hope you enjoy reading about what we and our clients have been up to over the last few months. Also as many of us start preparing for our much anticipated annual holidays with family and friends we wish you a wonderful, relaxing, and safe break wherever you may be going and whatever you may be doing. See you after the Summer!

CIA Awards

We were delighted to attend the prestigious 2017 Chemical Industry awards ceremony in June, at which we were excited to be shortlisted for the Chemical Industry Service Provider of the Year award.

The Award recognises the contribution of Service Providers to the success of the UK chemical industry. In particular innovation and outstanding delivery of services for example, engineering, IT, legal, training to the chemical or pharmaceutical sectors.

Unfortunately we didn’t win but we had a great evening celebrating our “near success” with a number of our clients who had joined us for the evening!

David Taylor, one of the Black Belts we have trained and certified collecting the award.

We were also delighted to have the opportunity to share on the success of Johnson Matthey, Edinburgh who are one of our longstanding clients. They won the the prestigious ABB Manufacturing and Resource Efficiency Award this year. This award is in recognition for the outstanding work the team in Edinburgh have been doing over the last few years driving performance improvements and instilling a culture of continuous improvement across the business.

We are proud to have been part of their ongoing journey – and we hope they have even more success in the years to come with many exciting things going on in their business including major expansion at a new site in Annan.

Uncovering Hidden Value With Our OPEX Assessments

Benchmarking your Opex Activities against best practice is a great way to assess strengths, weaknesses, and pinpoint focus areas for improvement. At Process Insight we have developed two benchmarking self assessment tools which we often use with our clients to help shape their programmes.

Recently Andy was invited to put these tools to powerful use in a different context – working closely with a Private Equity company, Pamploma, looking to to realise their investment in a high performance plastics company. These tools allowed us to showcase the operational capabilities of their business in a visible, data driven, and easy to understand way and to identify future value enhancement opportunities from broader Opex improvements. The findings and conclusions have had a big impact on shaping the company sales prospectus.

We have found the Process Insight Opex Assessments very useful in the due diligence process when both buying and selling companies. It gives us a great view on the comparative performance of an organisation that does not come through in the financials alone.

Derek Whitworth, Pamploma

If you would like to find out more about our Opex Assessments give Andrew a call on 07785 927144.

Where Are They Now?

We have been consulting for about 10 years and we thought as a regular feature of our newsletters it would be interesting to catch up with some of our first clients (and now friends) from those early days to find out what has happened to them across the intervening years. This time we feature Pete Marshall, currently working with Deloitte at the heart of the exciting new field of Robotic Process Automation and AI – one of the next big things in process transformation- so important in fact that Mark Carney (Governor of the Bank of England) believes it will represent the next industrial revolution!
I left one of the Big 4 management consulting companies with the ink still wet on my BB certification in 2007. Having spent the last 9 years or so running LSS projects and getting my MBB certification in 2011, I became more interested in the predictive/machine learning side of statistics and completed a Graduate Certificate in Applied Stats and Data Mining in 2016. I am now cross-training into automation using RPA and am now building robots in Blue Prism and UiPath. In the next 12 months or so I intend to bring together the combination of Lean, RPA and machine learning to deliver a “hard to beat” skillset. None of what I am doing now would have materialised if I had not done my Black Belt certification with the 2 Andy’s 10 years ago!…

Congratulations To All Our Recently Accredited 'Belts'

At Process Insight we believe very strongly in people development, skills transfer and capability building. Consequently we are particularly delighted to offer our congratulations to those we have recently coached & certified. Certification represents a very important milestone in an individual’s personal development and is a great demonstration of sustained leadership & business impact. If you would like to find out more about becoming accredited then give us a call.

Master Black Belt certification

Angus Livingston
Gillian Macleod
Nick Adams
Lachlan Mellings

Green Belt certification

Luisa Lovato
Edoardo Corradin
Daniele Radin
Michele Andreani
Lidia Zantedeschi
Paolorita Passarelli
Emiliano Sulprizio

Help Shape Our Next Networking Event

We are planning a client networking event after the Summer based around the theme of “Leading Change”. We would love your input to help shape the event and make it really relevant to your needs. If you have 5 mins to spare please click on the link below to complete a short survey so that we can hear your VOC. Many thanks!
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Save the date! PICL Networking Event on RPA

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Latest company updates and industry news

Save the date! PICL Networking Event on RPA

RPA (Robotic Process Automation) is the next “big thing” in process improvement in service & transactional.

We have all heard about it – but many of us need to better understand what it means. Is it the death knell for lean or a fantastic opportunity for LSS professionals? Either way it will affect all of us.

At Process Insight we are thinking about what it might mean for our consulting offer. You may be thinking about what it means for you and your programmes.

If you are interested to explore this further then “save the date” and plan to join us at our networking event in Edinburgh on the 13th October 2017.

More details will follow in the next couple of weeks.

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Insulin Pen Manufacturer – Batch Record Error Reduction

Case studies

See how we have helped clients across many sectors solve their business problems and deliver tangible benefits

Insulin Pen Manufacturer – Batch Record Error Reduction

Insulin Pen assembly and packaging operation with throughput of 115 million pens per year. High error rate in batch records resulting in significant (weeks) delays, inventory build up awaiting release, and high level of QC effort spent resolving issues (4 hours per day)

Case-Study-Pharma-Batch-Record-Error-Reduction

56% error rate due to missing signatures, missing data, incorrect times and dates.
Unclear explanations for line stoppage and quality events.
Goal – Right First Time (RFT) for batch records of 75% by end 2013

Problem tackled using Rapid Improvement Kaizen approach.
50 improvements proposed.
15 improvements implemented during the event including:

  • Simplifying batch records
  • Visual management to track recurring errors
  • Improving definitions to clarify and mistake proof

Further 30 improvements actioned post the event since required validation for
compliance.

Assembly – RFT increased from 39% – >50%.
Packaging – RFT increased from 44% – >51%.
Trends suggest RFT target will be achieved by mid 2013 (6 months ahead of schedule).
Reduced QC workload allows 3 QC technicians to be transferred to new production
line.
Inventory reduced.
Estimated annual savings overall of 400,000 Eur.

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Global Biotech – Innovative Training Methods to Reduce Deviations

Case studies

See how we have helped clients across many sectors solve their business problems and deliver tangible benefits

Global Biotech – Innovative Training Methods to Reduce Deviations

A global biotech company suffering significant losses due to delays in starting up production. Additional major costs incurred in rework associated with deviation management.
Case-Study-Pharma-Innovative-Training-Methods-To-Reduce-Deviations
In one year alone the formula tion support team raised 88 deviations during the ramp up phase of 98 process change projects. As a result, 25% projects were delivered late. The goal was to reduce the number of deviations during ramp up of production during process change by 50%.
3 day kaizen event involving operators and technicians. Key Improvements:
  • A more effective, standardized method of training operators in new validation protocols.
  • Operator involvement in defining the content and the most effective method of training to meet their needs
  • Clear definitions of roles and responsibilities during validation protocol training and process management
  • A template for the training manual which trainers adapt to meet the specific needs of the process change protocol (SOP)
  • Weekly process reviews with operators to review issues, propose and implement solutions and sustain the improvements
Three month after implementation ZERO deviations were raised during 20 validation runs. Operators also reported that the new training methods removed a lot of the frustration and rework. Estimated annual savings of over €700,000.
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