Case Studies | Research | Useful Links

Sector:


Cryovac

Background

  • Part of Sealed Air Corporation
  • Manufacturer of packaging materials for the food industry
  • 400 employees
  • Seven day operation with separate weekend/weekday shifts
  • Unionised environment

Problem

  • Disjointed teams with different cultures
  • Excessive overtime working and high overtime component to pay
  • Entrenched positioning and tradition
  • Increasing competitive pressures
  • High cost manufacturing site
  • Lack of flexibility
  • Holiday shutdowns causing production problems
  • Seasonal business

Outcome

  • Shift patterns developed to take account of seasonality
  • Totally changed pay system, new pay bargaining system
  • Department improvement teams
  • Transfer of low grade maintenance to production
  • Supervisors to staff contracts
  • 51 weeks manufacturing
  • End of weekend/weekday split
  • Stability of hours and earnings
  • Greater efficiency and need for less stock

DS Smith Packaging

Background

  • Part of DS Smith Plc
  • Manufacture of fibre-based packaging and related services throughout multiple sites in the UK.

Problem

  • Lead times too high
  • Unit cost too high
  • Volatile market not being matched

Outcome

  • Flexible hours implemented allowing productive hours to vary daily in line with changeable demand
  • Targets of shorter run lengths, reduced lead times and lower cost met
  • Employee skills base broadened to cover a variety of machines
  • Teams restructured resulting in more stable competitive cost
  • New pay structure

Sector:

Case Studies | Research | Useful Links

 Rosette
Blue Bar

"The gains not only drew in our costs but substantially improved our flexibility to respond in a fiercely competitive market"

Managing Director, Dawson International Subsidiary Company

Blue Bar

"Our Plan 2000 was designed to position Guinness in Dublin as a world class operation. Annual Hours was a central plank of our overall strategy, and Pasfield Curran consultants were able to assist us with their expertise in this area, allied to a wide knowledge and experience of the overall organisational factors involved in a major change programme"

Matthew Murphy, General Manager, Guinness

Blue Bar

“With the help of Pasfield Curran we now have a truly flexible workforce which genuinely reacts to daily workload fluctuations to meet customer needs. We now achieve 99.9% service level everyday at no extra cost”

Michelle Cook, Operations Manager, Boots the Chemist

Blue Bar

“Operating in an international market where customers must be satisfied immediately otherwise competition will step in, means we must constantly search for new ways of working. Matching workstyle with lifestyle is the key to success. In partnership with our staff and help from Pasfield Curran we moved from 5 days a week to 7 day working”

Kevin Riddett, Operations Manager, Motorola

Blue Bar

“Prior to the project we thought we were quite good communicators but the work we did with Pasfield Curran led us to a higher plane”

Tony McGrath, General Manager, Rhodia

Blue Bar