SOLUTIONS FOR THE
MANUFACTURING INDUSTRY

Empowered Business Transformation

Manufacturing businesses face a unique set of challenges competing in today’s global market. Maintaining profits in spite of tightening margins and increasing competition is often an uphill battle.

Big Change Agency creates a high performance environment by seamlessly incorporating people, processes, and technology. Through building a culture of empowered and engaged employees aligned with clear company goals and processes, productivity soars and profits increase.

We define a successful program as the following:

  • Produces measurable results from day 1
  • Delivers a 3 to 1 Return on Investment over a 12 month period
  • Creates a self-sustained culture of continuous improvement

PROBLEMS
WE SOLVE

  • High staff turnover, absenteeism, and unproductive workers who are just there for a pay check
  • A reactive maintenance culture with high and unpredictable machinery downtime
  • High levels of waste and scrap
  • Constant firefighting, causing your managers to be constantly reacting instead of innovating
  • Colitics and infighting between departments, together with hidden agendas holding the business back
  • High customer complaints with little ownership from the factory floor And more

THE BIG
DIFFERENCE

We drive profit enhancement through culture and systems improvement. While we optimize your systems and solve problems that give your business back its competitive edge, we also focus on one important business element many of our competition overlook – people.

Our approach focuses on your people and culture as the frontrunners of effective business transformation. We firmly believe you can only improve your bottom line through your people. Why? Because your people run your business. No matter how much technology you have in place, at the end of the day it’s your workers who implement the systems your business needs to run efficiently and profitably.

You can spend millions of dollars training your people in the latest tools and methodologies – but if your workers don’t believe in it, they won’t use it. Without 100% buy-in from your staff, tools and trainings are just numbers on a board that aren’t actually doing anything to drive your business forward.

The bottom line is that cultural engagement must come before any operational improvement. Organising and motivating your team to adopt a culture of continuous improvement enriches the lifeblood your business lives (and dies) by.

What We Do

Our approach is to look at your business as a whole, detect the biggest problem areas, give you the tools to fix them, and ensure these solutions are fully implemented on an ongoing basis. Our powerful blend of the right technology with effective cultural change gives us a 100% success rate across dozens of successful business transformation projects.

Culture & Change
Management

We work with your people at a grass roots level to empower and motivate them to operate at their best capability. When people are engaged with what they’re doing, waste decreases, efficiency improves, and profits rise.

Profit Enhancement

We work with your people at a grass roots level to empower and motivate them to operate at their best capability. When people are engaged with what they’re doing, waste decreases, efficiency improves, and profits rise.

Efficiency & Continuous
Improvement

We offer effective solutions and business tools to solve your biggest problems. Then we train your workers on the tool or methodology so they can troubleshoot and solve these types of problems without our input – effectively teaching them how to fish.

Maintenance Excellence

We drive overall equipment effectiveness improvement and maintenance reliability for a smoother running operation with less wastage and enhanced productivity.

“Happy workers are 12% more productive than the average worker, and unhappy workers are 10% less productive. In fact, unhappy employees cost American business over $300 billion each year.”
— University of Warwick

OUR
METHOD

Big Change Agency uses a 4 pillar approach for establishing lasting cultural change, improving systems and driving greater profits.

PURPOSE

Why your business does what it does, it’s vision, mission, values, standards and how your employees align with your overall goals.

PROCESS

Looking at every part of the business process, not just the processes themselves, but the business as a whole holistically.

PERFORMANCE

Encouraging better performance from your people and your processes, measuring how you’re doing and creating a culture of continual improvement.

PEOPLE

Empowering your employees from every part of the business to make changes and understand the part they have to play through driving improvements.

CASE STUDIES

Enterprise

Initial Situation:

At the beginning of this 12 month period the plant was running with 2 production lines with a capacity of 16,000 loaves of bread per hour. DIFOT was being maintained at a high level but only through significant overtime. Plant KPI’s were in place and were running at an overage of:

Improvement Approach:

The approach taken to make improvements was based around rigorous analysis of production and engineering data combined with rapid implementation of corrective actions.
Twice daily the improvement team would collect production data including detailed descriptions of all downtime and causes of waste. Through the analysis of a standard Pareto chart each day the top 2 reasons were fully investigated and corrective actions put in place to ensure there was no recurrence.

The Results:

Improvements in machine reliability in an industrial bakery environment quickly flow through the business.
Less breakdowns mean less waste and more consistent production. This in turn led to more consistent quality, more reliable deliveries and an overall improvement in the consistency of business operations.

Business

At the beginning of this 12 month period the plant was running with 2 production lines with a capacity of 16,000 loaves of bread per hour. DIFOT was being maintained at a high level but only through significant overtime. Plant KPI’s were in place and were running at an overage of:

Initial Situation:

Running 16 hour production shifts each day and with a new contract about to come on line this bakery had an urgent need to increase line output to enable additional volume to be made on the existing line.

On the line downtime, waste and giveaway were recorded manually with pen and paper and these figures were presented to the management team on a weekly basis. It was not the norm for this critical production information to be filtered down to the front line staff and there was not usually any pro-active follow up on the issues that were recorded.

Improvement Approach:

After spending time observing the line in operation it was evident that there was excessive downtime and giveaway that was not being recorded or acted upon. LiveBake initially undertook a staged approach to data collection:

  • Establish an Excel spreadsheet to collate and communicate the recorded line measures, at this point it was found that 20 minutes downtime and 4% giveaway a day was being recorded
  • Introduce LiveBake computer data entry point to replace the traditional pen and paper, this gamification increased the recorded downtime from 20 minutes to 60 minutes and the recorded giveaway from 4% to 5%.
  • Connecting LiveBake directly to the line equipment to gain exact downtime measurements led to the recording of over 150 minutes of downtime per shift and an increase in giveaway recording to 7%

Baseline:

This process completed over the period of 4 weeks allowed the establishment of the project baselines:

Factory In Your Pocket - Improvement Approach:

The creation of the base line or ‘current state’ enabled both the bakery and LiveBake to agree on the next course of action; reduction in downtime and giveaway.

A project team was established to drive these improvements using both LiveBake standard reports and detailed Factory in Your Pocket analytics provided through Yellowfin software. Using standard improvement techniques combined with formal Root Cause Analysis and 5-Why investigations the team was able to identify and reduce the causes behind significant downtime and excessive giveaway. information to be filtered down to the front line staff and there was not usually any proactive follow up on the issues that were recorded.

Results:

In this project the Giveaway savings were a direct impact to the bottom line profit of the business. The total cost benefit to the business was $375,000 per year.

Factory in Your Pocket worked with and supported the site team over a period of 4 months, since the completion of this project the team have been able to undertake similar analysis and improvement without external support.

Our Guarantee

The team at BIG Change Agency stand by our results.

We offer a ROI guarantee on programs based on performance measures we set together with our clients.

This means that if the program does not achieve the ROI promised, we refund the difference. We are pleased to report a 100% success rate across dozens and dozens of successful business transformation projects.

Get your free trial of Factory In Your Pocket!

Less WASTE. More OUTPUT. Less SURPRISES. More PROFIT.

Manufacturing is a tough game to be in and it is easy to get lost in paperwork and confusing data.

Factory In Your Pocket develops streamlined processes and software for automated data collection and presents only useful information using the award winning Yellowfin BI.

logo
MELBOURNE   |   JAKARTA   |   KUALA LUMPUR

Log in with your credentials

Forgot your details?