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LEADING THE FIELD.When Irish Dairy Board wanted to create a culture of ContinuousImprovement at 3 plants in Europe, it asked Celerant Consultingto get down on the ground and help drive results up.rish Dairy Board was looking toIimprove operational efficiency inanticipation of the increase in dairyoutput forecast from the removalof milk quotas in 2015. The Executive ManagementTeam therefore decided to launch a LEAN Initiativeto align operations and introduce a culture ofContinuous Improvement into the business,starting with three key locations in Europe.After a competitive bid process, they identifiedCelerant Consulting as the ideal partner to makethis happen by introducing the new behavioursthat would be needed to create this culture ofContinuous Improvement.Rising to the topThe project started with the deployment of anOperations Excellence initiative across the threeEuropean sites to develop new ways of workingbased on LEAN Principles and internal best practice.Celerant focused on standardising OperatingProcedures and installed Short Interval Controlsto improve process stability. Kaizen events wereperformed with Operators and Team Leaders whichfocused on standardising operating proceduresand improving product flow.Celerant also introduced a comprehensive MCRS ®Management System that enabled the three sitesto standardise their performance measures andimplemented a Root Cause Analysis and escalationprocess to eliminate production issues.LEAN training and behaviour coaching at alllevels of the organisation, from Plant Managersto Operators, helped to embed these newchanges and create the culture of ContinuousImprovement that was evident by the improvedOEE and Yield KPI’s.SUSTAINABLERESULTS• The project was completed in 30 weeksand rolled out across all three sites.• 5S audit scores measuring workplaceefficiency and effectiveness improvementsrose from 60%- 85%.• System Implementation Status auditsachieved a level of 80% at all sites, whichmeans that real behavioural change hastaken place and a culture of ContinuousImprovement has been created.• By project end more than 40 ProductionTeam Leaders were trained and certifiedin LEAN, led by Continuous Improvementchampions at each site, with ownershipfor sustaining these results.CLOSEWORK® GLOBAL REVIEW 2012 41