1

OPERATIONS ALIGNMENT

STABLE OPERATIONS TEAMWORK

ASSET CARE 5S

QUALITY SET-UP TIME REDUCTION

ENVIRONMENT, HEALTH AND SAFETY ENVIRONMENTAL SUSTAINABILITY

VISUAL MANAGEMENT USER-DRIVEN MAINTENANCE

FOCUSED IMPROVEMENT ADMINISTRATIVE EXCELLENCE

BEST-IN-CL ASS OPERATIONS PRACTICES in process manufacturing deliver 97% on-time deliv-ery; 89% overall equipment effectiveness; and a 26% reduction in total cost to manufacture. In fact, you can expect to uncover up to 20% of newly available capacity from the ‘hidden factory’.

traccsolution.com

OPERATIONSBEST PRACTICES

MAKE

I M P R OV EWHAT DO YOU NEED TO

TO ENSURE BEST-IN-CLASS

MANUFACTURING& PROCESSING?

1

IMAGINE ...

IMAGINE a powerful improvement solution that grows and evolves as your needs change and your improvement practices mature.

IMAGINE being able to monitor and drive improvement activities across your entire global business and value chain from one single dashboard.

IMAGINE your people engaged around processes, and passionate about results, improving practices and consistently driving performance.

IMAGINE harnessing all of this to progressively build and entrench a business system which is your defining differentiator that cannot be copied.

...

One solution to align and integrate

your improvement strategy

2

Together, these best practices enable your people to secure alignment and cooperation across functions and departments, build and support the human capital that is necessary to reach world class, and manage the journey in a manner that keeps everyone engaged.

INSIDE THIS SOLUTIONThe TRACC Operations Best Practices integrate all your improvement processes into one cohesive system that aligns your practices to your strategy and ensures sustainable results on your world class journey. This integrative improvement system drives world class best practice irrespective of leadership changes, mergers and acquisitions and your operation’s preferred language, making it a scalable source of competitive advantage.

BEST PRACTICES INCLUDE:

TRACC’S THREE CORE IMPROVEMENT STRATEGY AND ENABLEMENT BEST PRACTICES

PLUS

LEADING AND MANAGING CHANGE

VALUE CHAIN ALIGNMENT

HUMAN CAPITAL

Operational excellence improves effectiveness and efficiency while minimising costs without reducing value. It standardises and integrates best practices to enable your people to implement improvements simultaneously across multiple plants. And it builds the motivation and capability to improve performance, practices and work processes continuously.

OPERATIONS ALIGNMENT

STABLE OPERATIONS TEAMWORK

ASSET CARE 5S

QUALITY SET-UP TIME REDUCTION

ENVIRONMENT, HEALTH AND SAFETY ENVIRONMENTAL SUSTAINABILITY

VISUAL MANAGEMENT USER-DRIVEN MAINTENANCE

FOCUSED IMPROVEMENT ADMINISTRATIVE EXCELLENCE

OPERATIONS BEST PRACTICES

3

IS THIS SOLUTION FOR YOU?You need to align departments and functions in the supply chain to reduce conflict at the site level. You need to ensure that processes, technologies, people and improvement initiatives are synchronised and coordinated throughout the end-to-end supply chain to meet customer expectations. And you need to ensure that this alignment in operations is the starting point for developing differentiated capabilities in your organisation’s new value chains.

Align departments and functions in your supply chain for

sustainable performance improvement

The Operations Alignment TRACC aims to drive and coordinate improvement activities within operations and align the site with the rest of the supply chain to achieve sustainable performance improvement. It focuses on rapidly deploying improvement capability into areas where quick wins can be secured. And it focuses on the impact of digital transformation on the site operations, and how the site can exploit these new technologies to optimise costs and deliver value across the manufacturing network.

The Operations Alignment TRACC enables … • Alignment of the site’s performance by driving objectives and targets from

business to supply chain to operations strategy to performance targets at site level

• Alignment and coordination of the implementation of operations best practices within the site and across sites

• A shift from an individual site internal focus to external customer focus• Establishment of a daily management system to routinely address and resolve

problems• Alignment of processes internally and integration of site processes with

planning, warehousing, transportation, procurement and new product development

• Integration and optimisation of capacity across the entire manufacturing network

• A focus on the effects of digital transformation technologies on the site

OPERATIONS ALIGNMENT TRACC

OA

4

IS THIS SOLUTION FOR YOU?You need to identify, understand and manage systemic process variation. You need to create and maintain a high degree of operational (process) stability. And you need to ensure a consistent and dependable flow of output.

Unlock 15%-20% additional plant capacity with

Stable Operations

The Stable Operations TRACC prescribes a way of running and managing a manufacturing facility that is based on creating and maintaining a high degree of operational (process) stability. It leverages big data to deliver new insights and provides a faster way to scale predictable, reliable and stable manufacturing operations across multiple sites.

The Stable Operations TRACC enables … • Increased capacity with little or no capital investment• Reduced operating costs• Reduced inventories during peak demand periods• Reduced customer lead times• Higher levels of customer satisfaction

STABLE OPERATIONS TRACC

SO

5

IS THIS SOLUTION FOR YOU?You need to focus and mobilise your people to pursue strategic goals in an increasingly competitive environment. You need to establish effective work teams that are integrated into your site’s daily management system. And you need to help your employees gain greater control over their work life.

Maximise operational effectiveness with high performance

teams

The Teamwork TRACC helps organisations establish effective work teams that improve efficiency and drive down waste. It guides the progressive empowerment of work teams, ultimately leading to full self-direction. And it ensures that work teams are accountable for their performance.

The Teamwork TRACC enables … • Higher return on investment• Improved quality, productivity and service• Greater flexibility• Reduced operating costs• Faster response to technological change• Positive employee response to empowerment• The ability to attract and retain the best people

TEAMWORK TRACC

TW

6

IS THIS SOLUTION FOR YOU?You need to get the most out of your productive assets and avoid unnecessary costs to maximise profitability. You need to optimise maintenance activity to reduce total asset cost. And you need to maximise reliability, availability and longevity of machines.

Eliminate equipment failures and increase output with proper

asset care

The Asset Care TRACC aims to systematically align all physical asset-related policies, functions, programmes, activities and resources to the corporate business and manufacturing strategic goals. It addresses the people, processes and systems required to assure the desired balance of asset performance, cost and risk over the asset’s life. And it maximises the use of technology and Industry 4.0 practices in maintenance to achieve world class standards of asset care.

The Asset Care TRACC enables … • Improved asset availability, reliability and maintainability• Extended operational life of assets• Reduced overall asset lifecycle cost and increased profitability• Integration of the asset care function across the business• Application of data and systems technology to manage assets• Increased asset capacity and capability• More efficient asset maintenance processes and activities• Reduced negative impact on environment, health and safety• Preparation of the organisation for Industry 4.0

ASSET CARE TRACC

AC

7

IS THIS SOLUTION FOR YOU?You need to establish basic discipline, standardisation and orderliness to launch and sustain all best practices successfully within your organisation. You need to give workers a sense of ownership and pride in their workplace. And you need to establish clear work standards and visibility to improve product quality and reduce equipment deterioration, hazards and injuries.

Discipline, standardisation and orderliness that sustains best

practice improvement

The 5S TRACC ensures that work standards are set and sustained through self-discipline. It creates a foundation for other best practices to prosper and for your people to be their most effective. And it establishes an environment of responsibility, discipline and orderliness, which is fundamental to world class competitiveness.

The 5S TRACC enables … • Employee ownership and pride in the workplace• A more efficient maintenance regimen• Reduced set-up and changeover times • Better quality control • Effective problem-solving

5S TRACC

5S

8

IS THIS SOLUTION FOR YOU?You need to constantly pursue excellence by ensuring that product and service offerings are fit for purpose and keep improving. You need to meet and exceed customer needs both now and in the future. And you need to manage quality by focusing on customer satisfaction, prevention of defects, management responsibility and continuous improvement.

Exceptional quality that satisfies customer requirements

The Quality TRACC helps establish a culture of continuous improvement, quick wins and financial benefits. It advocates an integrated approach where quality principles become a way of life and a structured process is followed. And it offers a step-by-step process for achieving and sustaining quality improvements.

The Quality TRACC enables … • Defect reduction• Rework reduction• First pass yield increase• Inventory reduction• Reduction of customer order lead time • Reduction of manufacturing lead time• Reduction of new product introduction lead time

QUALITY TRACC

QU

9

IS THIS SOLUTION FOR YOU?You need to ensure that changeovers and set-ups are done in the shortest and most efficient way. You need to be flexible enough to respond quickly to customer demand without being bound by lengthy production runs and costly set-ups. And you need to minimise cost and waste to boost efficiency.

Cost, waste and efficiency improved with set-up time reduction

The Set-up Time Reduction TRACC reduces inventory levels and lowers working capital requirements as a result of shorter production runs. It improves production scheduling and predictability through the standardisation of changeovers. And it increases equipment utilisation through reduced set-up downtime.

The Set-up Time Reduction TRACC enables … • Higher production volumes• Improved production output and profits• The flexibility to respond quickly to customer demands • Reduced start-up wastes and rejects through efficient set-ups• Increased operator ownership and job satisfaction• Simpler set-up procedures that free up higher skilled people to focus on

improvements

SET-UP TIME REDUCTION TRACC

STR

10

IS THIS SOLUTION FOR YOU?You need to ensure the well-being of both the employees and the environment at large. You need to set in place the correct environment, health and safety policies and procedures. And you need to change the behaviours and attitudes of your employees so that the change is sustainable.

Reduce business risks and costs with Environment, Health and

Safety (EHS) excellence

The Environment, Health and Safety TRACC takes organisations from a position of indifference to a state where EHS excellence is the norm. It assists teams to highlight, address and progressively eliminate risks and hazards, thereby creating a healthy and safe workplace. And it engages all employees in developing, owning and sustaining a world class EHS culture.

The Environment, Health and Safety TRACC enables … • Prevention of injuries, lost working time and environmental incidents• Enhanced public image and increased employee morale• Increased productivity and enhanced employee relationships• A positive impact on surrounding communities• Improved product and process quality • Reduced costs by reducing EHS incidents

ENVIRONMENT, HEALTH AND SAFETY TRACC

EHS

11

IS THIS SOLUTION FOR YOU?You need to implement environmental best practices to improve operational and environmental performance in alignment with your corporate sustainability strategy. You need to identify and prioritise the most pertinent environmental issues, which may include energy and Greenhouse Gas (GHG) emissions, water and wastewater, waste, air pollution and Substances of Concern (SOC). And you need to set targets and establish management plans for each of these issues to achieve both incremental improvements and step changes in behaviour, technology and products.

Identify and manage risks with environmental sustainability

best practice

The Environmental Sustainability TRACC aims to support the corporate sustainability strategy and improve performance by guiding operations in the implementation of environmental best practices. It expands from an initial focus on internal operations and primary priority issues, to working with secondary priority issues and the organisation’s value chains to significantly improve operational and environmental performance, and ultimately influence change in the industry. And it facilitates engagement with local external stakeholders to the point where stakeholders are regarded as partners of the operation and organisation in delivering environmental sustainability.

The Environmental Sustainability TRACC enables … • The identification and management of environmental risk• Compliance with environmental legislation• Cost savings over the longer term• The enhancement of the organisation’s reputation• Access to financial markets• Increased employee motivation and retention• Product market opportunities

ENVIRONMENTAL SUSTAINABILITY TRACC

ES

12

IS THIS SOLUTION FOR YOU?You need an approach for managing and measuring the high-impact aspects of your business such as waste, quality and on-time delivery right at the point of production, by the people who work there and own that process. They need to understand what needs to be measured and figure out how best to measure it. And they need effective methods to collect, process and display this information quickly and easily to facilitate profitable decision-making in a digital environment.

Drive problem-solving, decision-making and focused

improvement through visual management

The Visual Management TRACC deploys, measures and displays performance measures at the level of the work team. It leads the drive to make the operation more transparent and efficient. And it shifts the emphasis from manual scoreboards to electronic displays and systems that produce real-time data that can be used predictively and prescriptively.

The Visual Management TRACC enables … • A high level of proactivity• Accurate and timeous information visually displayed for decision-making• Organisational performance visible and transparent to key stakeholders• Teams empowered to drive down waste actively and improve performance• Effective measurement of process outputs versus targets

VISUAL MANAGEMENT TRACC

VM

13

IS THIS SOLUTION FOR YOU?You need to take a team-based approach to maintenance activities to care for your assets effectively. You need to create a partnership between operators, maintenance personnel, engineers and operations management to eliminate unplanned downtime. And you need to free up skilled tradespersons for more specialist activities.

Eliminate 40%-60% of unplanned downtime with user-driven

maintenance

The User-driven Maintainance TRACC fosters equipment ownership among operators to enhance product quality, production efficiency and equipment lifespan. It helps prevent equipment failures by introducing proper asset care and early detection of minor problems. And it ensures operators become responsible for basic maintenance tasks, thus delivering improved equipment utilisation at lower overall cost.

The User-driven Maintenance Sustainability TRACC enables … • Greater ownership of equipment by operators• Redeployment of maintenance specialists• Increased operator skill levels and job satisfaction• Reduced equipment failures and downtime • Increased plant reliability • Reduced operational costs• Reduced maintenance overheads

USER-DRIVEN MAINTENANCE TRACC

UDM

14

IS THIS SOLUTION FOR YOU?You need to build a business system where the major wastes and priority areas in your business are identified and owned by the people closest to the process, and where these people focus effectively and relentlessly on driving improvements in these areas, with clear targets. You need to tie together all activities required to maximise the effectiveness of equipment, processes and people. And you need to rigorously eliminate losses and improve performance.

Improvement initiatives converted into real ‘value’ with focused

improvement

The Focused Improvement TRACC helps organisations identify major wastes and other underperforming areas, and addresses them through day-to-day problem-solving and specific performance improvement projects. It builds and integrates structured problem-solving capability to achieve focused sustainable performance improvements in other best practices such as asset care, quality, environmental sustainability and administrative excellence. And it ensures that the overall improvement initiative does not lose its focus in a maze of activities and practices that can result in failure and disillusionment.

The Focused Improvement TRACC enables … • Improved productivity, quality, cost, safety and delivery• Empowered and enabled front-line workers• Organisational learning through problem-solving• An understanding of key losses and their business impact• Enhanced teamwork across disciplines• Quick wins that drive the momentum and credibility of the change process

FOCUSED IMPROVEMENT TRACC

FI

15

IS THIS SOLUTION FOR YOU?You need to apply lean principles in your on-site administrative and support departments, as well as to work processes if your organisation is to become truly world class. You need to unlock and track the hidden value-adding activities within administration. And you need to set clear performance indicators and targets such as delivery, quality and cost to improve consistently.

Improved service delivery, quality and cost through

administrative excellence

The Administrative Excellence TRACC provides a step-by-step integrated improvement methodology for all the administrative and support departments and individuals on site. It ensures a systematic approach to embedding the principles of lean and process improvement. And it supports the implementation of teamwork, 5S, problem-solving and visual management best practices.

The Administrative Excellence TRACC enables … • Improved value delivered to customers through lean processes and work

methods• Application of basic planning tools to smooth demand and create customer pull• Improved problem-solving skills to drive performance improvement projects• Teamwork and leadership skills development• Management through the visual display of performance• Implementation of 5S for discipline, order and efficiency• Clear performance indicators and targets (delivery, quality and cost)

ADMINISTRATIVE EXCELLENCE TRACC

AE

16

TRACC SYSTEM COMPONENTS AND SUPPORTING FEATURES

TRACC is a robust and secure continuous improvement solution that delivers a fully integrated digitally-driven experience. Bring your improvement plans to life with TRACC’s digital ecosystem which offers tools and support to easily manage and accelerate global performance improvement.

The TRACC Integrative Improvement System allows you to:

TRACC PLATFORMSET TARGETS. FOCUS TEAMS.

TRACC Platform is a secure online platform that enables you to assess, plan, train, manage and report on your global improvement initiatives. TRACC Platform also includes the Mobile Assessor application which facilitates on-the-spot best practice improvement assessments while you walk the shop floor.

TRACC EXPLORER TAKE ACTION. STAY ON TRACK.

TRACC Explorer is an integrated and collaborative digital application that enables you to assign improvement plan work to teams. At-a-glance dashboards use real-time data to help you monitor progress at operational, regional and global levels.

TRACC ANALYTICSGet real-time data-driven analytics to help you uncover insights, patterns and trends based on your TRACC Platform activities.

TRACC TRAININGLEARN. ENGAGE. APPLY.

TRACC Training is a blend of self-directed eLearning and facilitator-led workshops designed to unlock your employees’ capabilities and accelerate learning and work process improvement.

TRACC READER

Get easy, mobile and electronic access to the TRACC best practice steps, shared learning and resources on your tablet (iPad and Android) and Windows PC.

TRACC Trusted Advisors are deeply experienced best practice implementation experts who are on hand to provide support and coaching through the more challenging aspects of your improvement journey.

TRACC TRUSTED ADVISORS

• Assess your best practice improvement opportunities• Plan focused work bundles to address improvement

targets• Train leadership and continuous improvement capability• Implement integrated best practices at multiple levels

• Manage global improvement progress with automated, dynamic reporting

• Share best practices and standards, through mobile platform capabilities

16

17

TRACC offers the following

best practices to help you

accelerate and sustain business

performance improvement

across your entire value chain.

INNOVATEPortfolio and Lifecycle Management

PLANStages 2-3

Demand Planning

Supply Planning

Sales and Operations Planning

Stages 4-5

Integrated Business Planning

SOURCEProcurement

MAKEOperations Alignment

Stable Operations Teamwork

Asset Care 5S

Quality Set-up Time Reduction

Environment, Health and Safety

Environmental Sustainability

Visual Management User-driven Maintenance

Focused Improvement

Administrative Excellence

DELIVERTransportation Management

Warehouse Management

SERVICECustomer Service Excellence

Transactional Excellence

ENABLEValue Chain Alignment

Human Capital

Leading and Managing Change

ENABLE

SUPPLIER CUSTOMER

BETABETA

TRACC VALUE CHAIN

IMPROVEMENT SOLUTION

We offer relevant advice, detailed guidance, change expertise, and software embedded tools and training that truly empower everyone in your business to

act with confidence as you drive towards world class performance.

For 30 years, we have delivered sustainable results across more than 3 000 operations, in 70 countries and multiple languages.

AFRICA/MIDDLE EAST+27-21-555-3610

CHINA+86-21-3382-1651

AUSTRALASIA+61-75-577-4005

EUROPE+44-207-321-3902

ASIA PACIFIC+65-6866-3300

LATIN AMERICA+52-33-3002-4023

NORTH AMERICA+1-949-679-2960

Think green. Think before you print.

TRACC, its logo, and Integrative Improvement System are trademarks of CCi.

traccsolution.com ccitracc.com

info@traccsolution.com

TRACC is produced by