Aggreko

Background

Aggreko provides rental power generators, temperature control equipment and compressed air systems to companies around the world. We help our customers increase profits by creating opportunities, solving problems and reducing risk using our unique network of global locations, equipment and technical services. Equipment for hire includes gas and diesel generators, loadbanks, heaters, air conditioners and chillers for planned and emergency projects.

Scope

Summing up our requirement here, we are running a 5S awareness event to kick start a project in the South West area. Initially we need to provide a level of education to the team to demonstrate the importance and benefits of 5S and its role in establishing operational excellence. At the end of the event I would hope that there is sufficient excitement and energy that we could put together a project team and plan for implementing this in the South West area, initially focusing on the operational organisation of our service centres and stores and later moving on to paperwork and administration. Subject to the project being a success, I suspect that other Aggreko areas (there are 4 in the UK alone) would be interested in conducting a similar exercise.

Method

The initial awareness day was arranged, with 12 representatives from Lee Mill, Port Talbot, Bristol, Midlands and Scotland manufacturing and service sites. In addition to 5S awareness, several simulation tools were used to help get the message across. One of the most powerful influencers was during the site tour/inspection we took photographs to highlight areas for improvement and project focus it was when we re-grouped and shared these photographs that there was buy-in to set-up a multi-site project team and initially focus on improving these areas at the Lee Mill Site. Approval and funding were given to start this European 5S initiative.
This multi-site project team (10 people) came to Lee Mill and spent four days going through the Sort, Set, Shine aspects of 5S focusing on the key areas highlighted during the awareness session. The focus was on the whole site from office areas, workshops, storage areas, washbays to the whole yard. Further work will be done to ensure that the Standardise and Sustain aspects of 5S are carried out to ensure sustainability.
The next site to be addressed is Port Talbot, with the project team taking full responsibility for this project and forthcoming sites across the UK.

Options and Recommendations

A 5S notice board was created within the Service Centre, initially with just the before photographs of areas that were to be addressed during the four day Sort, Set, Shine activity. This would later be updated with 5S highlights, best practice, project milestones, audits and before/after photographs to ensure sustainability
The initial photographs provided the inspiration and selection of areas to focus on and these were the areas addressed by the Project Team when they met on-site two weeks later.
With only three people running this site, it was essential that logical storage and placement locations were created to save considerable time for all activities.
Several areas had become dumping grounds and it was important to clear these areas to improve the overall look of the site. Lots of empty items were just stored and these have been removed/recycled to improve the environmental aspect of the site.
The workshops and containers had a strong focus and resulted in much more organised and efficient environment for working and searching. A move from floor storage to racking and wall storage has vastly increased the available working area, whilst improving the look and feel of the areas.
In addition to focusing on improving the Lee Mill site, this initial project was very successful at building the multi-site team and enthusiasm to improve all UK sites. At the same time lessons have been learnt with more planning time and on-site time being allocated to future projects.

Results

• Buy-in to 5S Culture
• Improved storage and organisation
• Reduced searching and wasted time
• 20% Space saving across the site
• 15% Improvement in productivity
• Visual work environment
• Continuous improvement

Further Actions 

• Improve site layout reduce shunting of equipment
• Improve flow on-site
• Complete outstanding actions
• Ensure sustainable improvements
• Lessons learnt for future sites
• Port Talbot focus

Customer Feedback

We now have a workshop and the workshop is better organised. "We found things we didn't realise we had." "Getting different people together from different depots. Could have done with more skips really needed 4 from day 1.You guys really helped us take those first steps towards creating a work environment that we can be proud of. More importantly the event marks the beginning of us setting and working towards a standard of service excellence which will become increasingly important as we look to grow our business