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5February2001LeanDiagnosticMetsecPurlinsThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quoted,orreproducedfordistributionoutsidetheclientorganizationwithoutpriorwrittenapprovalfromMcKinsey&Company.ThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussion.290101LNVST025JDAG-Diagnostics_V420100200300400500600700800Purlinsmarket%marketshare,£3630101059MetsecWardsStructuralSectionsAyrshireAlbionOthersAveragepricepertonneMetsecvalueproposition•customerservice&flexibility•design&technicalsupportpre-specifiedbymanystructuralengineersSource:MetsecSales290101LNVST025JDAG-Diagnostics_V43*Basedon2xhalfyearresults**BasedonhalfyearresultSource:MetsecaccountsMetsecbusinessunits23,68711,3199,1706,9076,3155,8255,4592,0381,988PurlinsHEPCRFMetstrutMetframeWindowsSupportsystemsProfilemanipulationEnergytubesSales*£000actualOperatingmargin**%actual9.3-5.912.0-1.04.170.75-3.612.18.8TonnesPIAplustarget2003290101LNVST025JDAG-Diagnostics_V44ThebusinessneedShareholdersexpectationsBusinessneedCustomerneeds•Raiseproductivityby20%•Reduceworkingcapital•Reducevariabilityofmanufacturingleadtimes•Developlong-termcapabilities•Growthebusiness•IncreaseROSfrom8.8%to15%by2003•Returnon£3Minvestmentfornewfactory•Demonstrateimprovementcapability•Leadtimesconsistently2weeks•OTIF>98%•Customercomplaints<1.2%Source:Team290101LNVST025JDAG-Diagnostics_V45ThecontextHowdowemakethemostofthenewfactory?290101LNVST025JDAG-Diagnostics_V46Agenda•Currentstate•Futurestate•Businessbenefits•Implementation•Currentstate•Futurestate•Businessbenefits•Implementation290101LNVST025JDAG-Diagnostics_V47WeeklydemandTonnes*010020030040050060070080090013579111315171921232527293133353739414345474951WeeksDemandOutput2000*exludesSFSandMetframe,accessoriesincludedas+5%byweightSource:Sales~capacity290101LNVST025JDAG-Diagnostics_V48Typicaldailydeliveries*Tonnes19880103131115Monday*WeeklyaveragefromJanuary2001Source:MetsecshippingandtransportdataTuesdayWednesdayThursdayFridayAverage=107Monday’sdeliveriescanbedoubletheaveragefortherestoftheweek290101LNVST025JDAG-Diagnostics_V49ServiceLevel%OTIF2000AprMayJunJulAugSepOctNovDecSource:Metsecreports88.091.294.393.680.984.687.181.690.54ordersbalancedperdayAverageTarget8898290101LNVST025JDAG-Diagnostics_V410Customercomplaints0.01.02.03.04.05.06.0JanFebMarAprMayJunJulAugSepOctNovDec242219141011Manufact-uringLoadingDrawingofficeLogisticsITOtherTotalcost=£93,00066%oftotalcomplaintsoutstandingatyearendQualitycomplaintsSource:Metsecreports2000%Deliveries1.2AverageTarget3.7290101LNVST025JDAG-Diagnostics_V411Productionsystemcosts£000s*202300294796CoilPurlinsCleatsTotal*WIPcostedat£368pertonne,exceptcleatsat£1.50/unitsource:Metsec,TeamanalysisOvertimeWorkinprogress1201209070400Bradbury1Bradbury2AccessoriesLoadingTotal2000ESTIMATE290101LNVST025JDAG-Diagnostics_V412Productionsystemdrivesperformancesource:Team•Quality•Cost•DeliveryProductionSystemInputsPerformanceSystem•Quality•Cost•Delivery!ProductionSystemmaterialsequipmentmanpower1Overproduction3Transportation2Waiting5Inventory4Over-processing7Motion6ReworkWaste290101LNVST025JDAG-Diagnostics_V41388%OTIF60%stocknotmovingin3daysCurrentProductionSystem4weeks1week1weeks’coilstock693TRollingOEE=20–40%c/o=10minLowlevelsofequipmentperformancePoorinventorymanag...