In order to increase its competitiveness, Pratt & Whitney Kalisz bases its Management System on the Continuous Improvement philosophy. It started in 1996-1999 with Kaizen workshops and TPM sessions at manufacturing cells and in administration and office units. The introduction of Kaizen contributed among others to optimum cell layouts, reduced batch sizes, reduced waiting for tools time (mini-cribs), reduced machine failure frequency rate and visualized work stations. Measurable benefits and employee engagement triggered further steps towards Continuous Improvement. In 1999 a separate cell was established to coordinate implementation of the Continuous Improvement Program ACE™ in PWK.
Built on Kaizen and TQM foundations, ACE™ focuses on the following actions:
- define and meet (external and internal) Customer expectations;
- define and improve processes;
- standardize processes;
- identify and solve current problems reported by Employees and Customers;
- reduce manufacturing leadtime;
- carry out preventive actions for the maintenance purposes (TPM);
- visualize work stations.
Actions Aimed at improving competitiveness of our goods and services fall under 13 ACE™ tools arranged according to specific criteria in the certification protocol. The tools are integrated, innovative, effective, and may be subject to evolution depending on specific applications. They include methods of communicating and means of monitoring progress owing to which Employees become interested in the Company objectives and find it easier to understand their contribution in accomplishment of such objectives.
ACE™ is a universal system and may be applied in all types of businesses regardless of the sort and form of ownership.
The actions make use of such common techniques as:
- process mapping
- brainstorming
- 5x why
- Ishikawa (cause & effect) chart
- Paretto chart
- SPC
- Decision Matrix
- Mistake Proofing
- Kanban
Another big step into the future as regards the Continuous Improvement domain is supporting ACE program in our Company with Lean Manufacturing philosophy. The combination of both philosophies enables PWK to be even more competitive and deliver on time as required by the Customer. Aided by LM experts Pratt & Whitney Kalisz can be proud of its first practical results in this area.
While aiming to achieve the top quality, since 1999 the Achieving Competitive Excellence (ACE) program has been in place, whose role is to engage all Employees in raising the quality of manufactured parts and improving Company operations at each organization level. An important element of the program is regular training of all Employees. In the same year Pratt & Whitney Kalisz launched the Scholar Program which supports all forms of employee educating process.