OPEN – Unlock Productivity image

Improvement Toolkit / OPEN – Unlock Productivity

Whilst it is great that Lean worked so well in Toyota, Six Sigma delivered for Motorola, and Nakagima found success with TPM – what is the right solution for you? 

All the above techniques were tailored solutions based on the teachings of Professor William Deming.  And what the first thing they did?  Understand that they had to tailor the approach for their sector.

Is the right thing to sweat your assets and strive for ultra high reliability?  The answer depends on your appetite for risk, and the depreciation/FTE to premium time running cost ratio.  Have you worked those out yet?  The answer is fundamentally important to determining whether you should touch TPM or not.

How much variability is desirable?  Close to zero is definitely possible – but if the legislation in your sector allows 1.6 Sigma of variation (as average weight legislation does for instance) – aiming for 6 could give your accountants, and your bottom line, a nasty headache.

The journey to Excellence is a long one.  Please don’t make it longer than it needs to be by starting down the wrong path.  Fortunately, the OPEN (Observe, Plan, Engage, Nurture) process can signpost the way for you, and unlock productivity as a result.

Through our 20 year experience of running guaranteed performance programmes, we have expertise about what does and doesn’t work that is unique.  To find out whether there is an easier path for you to follow, all you have to do is reach out!


We’ve had the best of our best, which are better than most, working on this for years and they have not achieved these results. This has clearly been a significant breakthrough. The results show this.

Senior Supply Chain VP from International Beverage Business

Over the past three months I have been concentrating mainly on changeover reduction, waste reduction and increased throughput. There has also been a challenge to behavioural patterns. All of these efforts have been using the knowledge that you gave me and I am delighted to say that all have been successful, culminating in increased throughput, less waste and an increase in OEE from an average of 78% to around 90%. There has also been a marked improvement with people issues.

Alwin Waterhouse, Improvement Manager, British Bakeries