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OPERATIONS BEST PRACTICES
www.traccsolution.com
BE S T- I N - C L A S S O P E R AT I O N S P R AC T I C E S i n p r o c e s s m a n u f a c t u r i n g d e l i ve r 9 7 % o n - t i m e d e l i ve r y ; 8 9 % ove r a l l e q u i p m e n t e f f e c t i ve -n e s s ; a n d 9 7 % r a w m a te r i a l u t i l i s a t i o n . I n f a c t, yo u c a n e x p e c t to u n c ove r u p to 2 0 % o f n e w l y a va i l a b l e c a p a c i t y f r o m t h e ‘ h i d d e n f a c to r y ’.
WHAT DO YOU NEED TO
IMPROVETO ENSURE BEST-IN-CLASS
MANUFACTURING
& PROCESSING?
Practices drive performance
In today’s competitive landscape, it is imperative that your
organisation learns to focus its efforts on BEST PRACTICES in a
way that sustains continuous improvement to meet the market
requirements. To do this, you need to address the deep question of
HOW WORK IS DONE by every single person, at every single workplace,
in every part of your business. And you need a business performance
improvement system to manage the improvement process.
We believe that by improving everything and enabling everyone, your
organisation will deliver sustainable world class results across its end-
to-end value chain, and be transformed into the ultimate source of
competitive advantage. If best practice is not embedded through an
improvement system, the step-change transformation opportunity is
lost and, over time, people in your organisation will slip back into their
old habits.
Most organisations in the food & beverage, chemical, FMCG and
pharmaceutical industries have been doing the good work of
continuous improvement in manufacturing and processing for years.
But typically, organisations take a project-based approach to this
work, resulting in sharp, short-term results. The real need is to build
capability across the entire organisation to sustain the results, and
to ensure consistent best practice standards and improvements are
implemented across global operations.
“SABMiller has enjoyed a 25-year journey with TRACC — capturing what works and tackling challenges together. The TRACC team is a great partner and sounding board, always bringing new knowledge and ideas into our organisation, helping us to test out new thinking.”
— Ed Koch, Head of Manufacturing Development, SABMiller
ONESOLUTION TO ACHIEVE YOUR IMPROVEMENT STRATEGY
Can’t go the distance
Contenders
Promising
Back of the pack
Stragglers
World ClassY
Perfo
rman
ce
Practice1 2 3 4 X5
We have spent the last 30 years helping organisations build
competitive capability in their manufacturing and processing
functions with the TRACC Operations Best Practices and our expert facilitation support in more than 2 000 operations,
across 70 countries and in multiple languages.
info@traccsolution.com |2| www.traccsolution.com info@traccsolution.com |3| www.traccsolution.com
Stage1
Stage 2
Stage 3
Stage 5
Stage 2
Transformation
Leading and Managing Change
Employee Engagement
Skills Development
Functional system improvementinitiatives via codified standardsAsset Care
HR Systems
Integrated Business Planning
Process FrameworksISO 9000
ISO 14000
Standard Work
TPMLean
Six Sigma
Expert Supported Projects
Organisational Design
Traditional Continuous Improvement
Structurebias
Executivebias
Impl
emen
tatio
n ve
rsus
Syst
ems/P
roce
ss p
redi
spos
ition
Project-based (Micro) change Broad Transformation (Mindsets and Behaviours)
INTEGRATIVE IMPROVEMENT SYSTEM
INTEGRATIVE IMPROVEMENT
Integrative Improvement is a comprehensive
business performance improvement approach
supported by a three-pronged philosophy
comprising the following: the arrangement of
an organisation around end-to-end processes
that serve customer segments rather than
functions; the involvement of all employees
in improving all processes and systems; and
committed leadership that actively creates
the mindset and behaviours within the
organisation to support these principles.
The ‘project-based approach’ to improvement
alone will only deliver incremental change,
and not the culture transformation needed
to create sustainable results and reach world
class. We believe the answer is ‘integrative
improvement’, which continuously integrates
WHY TRACC
We believe that sustainable competitive advantage hinges on 5 critical
success factors:
1To really win with the customer, you need more than a series of improvement projects. The required culture change can
only be realised by implementing an overarching business performance improvement system to drive the improvement
work in a way that will harmonise the interactions between your organisation’s people, processes and systems to better
serve your customers. This new system must deliver integrative improvement. WORLD
CLASS COMPETITIVENESS
people, processes and systems across functions, levels of work, and stages of best practice maturity into the transformation process.
Transforming organisations is a complex process. In our work over the last 30 years, we’ve seen, time and again, that the improvements
made by companies with armies of consultants and many disconnected improvement projects are simply not sustainable. They are
not externally focused enough and tend to result in one part of the operation being optimised while other parts fail to keep up.
The TRACC integrative improvement framework will help your organisation build standardised and integrated best practice and world class performance capacity across your manufacturing and processing functions. Simultaneously, it facilitates cross-functional collaboration to segment your customers and define your value streams, creating visibility to sense demand and build world class, end-to-end value chains to deliver to your demand requirements. TRACC aligns all your people to common SERVICE, COST and CASH metrics enabling the organisation itself to become the ultimate source of sustainable competitive advantage.
info@traccsolution.com |4| www.traccsolution.com info@traccsolution.com |5| www.traccsolution.com
“Before we implemented TRACC, we were investing in the same improvement projects over and over again. TRACC’s standard improvement framework solved this problem for us.”
— Donald D. Wirth, Vice President — Global Operations, Corporate Supply Chains, DuPont (Retired)
Practices drive performanceOrganisations need codified best practices in increasing stages of maturity to
drive all functions and processes towards best-in-class practices and competitive
performance.
ES
LMC
TW 5S VM FI
EHS
AM AC STR QU AE
Improvement must be integrativeOrganisations must move beyond a ‘project-based’ approach and take an integrative approach to Continuous Improvement
(CI). Best practices must be integrated across functions to break down silos and improve people, processes and systems
simultaneously. An integrative improvement system is needed to transform the organisation across three dimensions:
1. Operating practices
2. Enabling systems — all its tiers, operational practices, enabling systems and governing principles using an integrated approach
across all functions where each new component of change becomes ‘The way we do work’.
3. People — an incremental sequence of improvements, with skills development delivering behavioural change that will transform the
organisation and its people. The implementation approach must develop the best practice maturity of the organisation incrementally.
Transformation to world class, while taking care of all three dimensions, ensures integration between practices and processes, fundamentally
changing HOW WORK IS DONE by every single person, at every single workplace, in every part of your business. This culture and work process
change ensures sustainable results over time.
WHY TRACC
Improvement must move beyond the factory walls To drive marketplace success, organisations need an unblinking focus on segmented customer needs, rather than on internal
functional metrics. One size does not fit all, but a common improvement framework is needed to drive improvement across
all of the core business processes — from enabling people to innovation, through to planning, sourcing, manufacturing and
delivery to customers. Creating reliability in delivery in manufacturing operations is the critical starting point. This is where TRACC enables
organisations to design and develop processes and build skills and competencies first. However, it cannot be the only place on which you focus
your improvement strategy. To create the capability for breakthrough results and build the collaboration between functions, TRACC ensures
that all your cross-functional leaders and teams are invested in the outcomes of customer segmentation and the network reconfiguration
needed to design demand-driven value networks. TRACC collaborative teams at various levels help to focus functions on rapid joint problem-
solving and on shared cost, cash and service goals. This cross-functional improvement process really starts taking effect during Stage 3 of the
best practice maturity journey. It is at the end of Stage 3 in TRACC that this breakthrough work happens. All functions collaborate to design
joint KPIs and design demand-driven value networks (DDVN) that dynamically sense and supply to demand for each customer segment.
Depending on which industry you play in, 55% to 85% of the improvement opportunity sits outside of the factory walls once this cross-
functional collaboration takes place at Stage 3.
Operating Practices and Tools
Enabling Systems
People
Inte
grate
Sust
aina
bilit
y
Transformation
1 2 3 4 5
more than just tools...
Sustainable implementation requires that the tools integrate
into an operating system and are bound by clear management
principles into a complete framework.
…an integrated approach…
Implementation cannot be done functionally. Each new component of change becomes “The way we do work.”
…incremental sequence of implementation…
Transformational, behavioural-based change requires an evolution of the organisation and its people.
The implementation approach must incrementally develop the
maturity of the organisation.
Typical Business Transformation Results between Stages 3-5:• 20%
improvement in Perfect Orders
• 10% reduction in Costs (COGS, Supply Chain, Admin)
• 33% reduction in inventory
• 30% improvement in Overall Equipment Effectiveness
AM Autonomous Maintenance AC Asset Care STR Set-up Time Reduction QU Quality
AE Administrative Excellence EHS Environmental Health and Safety 5S 5S TW Teamwork
VM Visual Management FI Focused Improvement LMC Leading and Managing Change ES Environmental Sustainability
KEY
Businesses ultimately compete through the operational capability of their supply chains. A business needs to understand its customer
segments and proactively build value chains that can uniquely service these customer segments. An integrative improvement system takes
the concept of a production system from manufacturing across the end-to-end supply chain and allows a company to improve functional
capability within the context of building value chains that service specific customer segments, improving collaboration across functions to
ultimately enable demand sensing and shaping capability.
2 3
Stage 1 Stage 2 Stage 3 Stage 4 Stage 5Silo Thinking Customer Alignment Extended Alignment Demand-drivenInternal Alignment
Fully integrated extended network
Extended, consolidated, aligned and
balanced
Differentiated value chain development; Multi-
functional process teams
Functional competency, project driven, early
segmentationSilos, conflicts, unfocused
Busin
ess P
erfo
rman
ceYear 1 Year 2 Year 4+ Year 5+
Building a culture of problem-solving and empowerment
People working across functions towards joint KPIs
Bette
r cus
tom
er ex
perie
nce
Incr
ease
d m
argin
s
Impr
oved
velo
city
Optim
ised a
sset
s
TRACC delivers sustainable continuous
improvement
TRACC delivers breakthough business
transformation
Transformation Zone 2 :
Collaborate and align with
functions across the supply chain
to build DDVN
Transformation Zone 1 :
Design and develop processes and build skills and
competencies to ensure reliability
in delivery
Tran
sfor
mat
ion
Zone
1
Tran
sfor
mat
ion
Zone
2
info@traccsolution.com |6| www.traccsolution.com info@traccsolution.com |7| www.traccsolution.com
Build skills and a common language through workshops and eLearning
Self-assess to identify improvement opportunities
Plan and execute improvements according to an integrative, maturity-based road map with clearly defined improvement work packages
Share learning and rapidly evolve best practices
WHY TRACC
4 An engaged and enabled workforce is criticalOrganisations need to engage all of their people to
drive the improvement transformation under the guidance of
their internal improvement experts and a small team of external
advisors. The external consultants must be committed to building
internal capability and a culture of excellence that enables the
people in operations and the various functions to make the changes
themselves. The ultimate competitive advantage is the organisation
itself through the ongoing work of every single employee. It is
mission critical that the transformation process be owned and
driven internally.
TRACC challenges mindsets and behaviours through an inclusive
change management process, detailed guiding framework and
a training approach that is designed to be delivered by internal
TRACC-accredited trainers. This is supplemented by blended
eLearning materials, where appropriate, to provide cost-effective
skills development. One of the critical success factors is that TRACC
delivers change management and skills development workshops for
every stage. About 95% of the improvement work triggered through
using the TRACC Framework is action-based, with training making
up around 5% of the activities. TRACC provides workshop material
and training to develop skills just-in-time to various teams along
the way, designed on the 70:20:10 learning principle, with the real
learning happening through actually doing the improvement work.
This builds the capability needed for each step in the improvement
journey.
Enable your people with an integrative improvement
system that makes improvement a way of life.
Systemisation of improvement ensures sustainabilityTRACC is the only solution that provides an integrative
improvement online production system that delivers sustainable
business improvement results through best practice and work
process improvement. The system enables you to assess your best
practice and identify opportunities and losses; plan your step-by-
step performance improvement process; implement improvement
work bundles through the ‘How To’ implementation actions in
the system; track your progress and benchmark your operations;
manage your implementation plan against a proven improvement
methodology; and share best practice and build internal capability.
5
THE TRACC SYSTEM:• Aligns implementation activities with organisation maturity
• Focuses on developing people in all functional areas to own
and create process-based operational excellence
• Improves operating capabilities through process and policy
consistency
• Integrates continuous improvement processes and systems
(WCM, TPM, TQM, Lean, Six Sigma) into an integrative approach
TRACC SYSTEM COMPONENTS:TRACC Platform
The TRACC Integrative Improvement System provides a secure
online platform and application that enables you to assess your
organisation’s practice gaps, maps out the recommended sequence
of best practice and process improvement steps, and provides the
work packages to action these improvement steps.
TRACC Reader
The system includes an application for tablets (iPad and Android)
and Windows PCs that provides TRACC users with easy, mobile and
electronic access to the TRACC best practice steps, shared learning
and resources.
TRACC Training
The TRACC Platform includes training programmes and materials
designed to be customised and delivered by internal trainers. The
training methodology enables companies to be competitive by
unlocking the inherent capabilities of employees at all levels.
TRACC eLearning Cogs
The TRACC Solution provides online learning with overviews of each
best practice to ensure newcomers or latecomers to the process are
given the opportunity to accelerate their understanding of each
practice and work process improvement.
Businesses ultimately compete through the operational
capability of their supply chains. A business needs to
understand its customer segments and proactively build value
chains that can uniquely service these customer segments.
An integrative improvement system takes the concept of a
production system from manufacturing across the end-to-
end supply chain and allows a company to improve functional
capability within the context of building value chains that
service specific customer segments, improving collaboration
across functions to ultimately enable demand sensing and
shaping capability.
TRACC Training
TRACC Platform
TRACC Assessor
TRACC Reader
TRACC eLearning Cogs
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How does TRACC
deliver to these critical
success factors
Building a truly world class organisation requires a defined
framework for improvement action which enables the
whole organisation, and which takes account of the specific
needs and maturity at each local workplace. This allows people to work
separately but simultaneously on improving the whole organisation.
Without such a framework, sustainable success is unlikely.
The TRACC Framework provides a road map that guides all operations
and functions towards best-in-class, no matter what stage of maturity
they are at.
1 2 3 4 5
BEST PRACTICE MATURITY STAGES
STATUS QUONO
BEST PRACTICE
STABILISATIONAND
AWARENESS
OWNERSHIP AND
IMPROVEMENT
REFINEMENT AND
TECHNOLOGY
WAY OF LIFE(WORLD CLASS)
A five-stage best practice maturity framework with assessment and
improvement work packages.
We have created a science of best practices — a five-stage maturity
framework which lays out the road map of codified best practice and
business process maturity across your entire manufacturing and
processing network. Firstly, TRACC is focused on creating capability
and empowerment to deliver reliability and productivity gains in
all your plants. By Stage 3, TRACC has delivered well-entrenched
ownership of improvement by all operational teams, enabling plant
leaders and teams to collaborate across the supply chain with their
colleagues in innovation, planning, sourcing and delivery to create a
fully integrated value network in Stages 4 and 5. This framework has
been designed to unlock continuous improvements in SERVICE, COST
and CASH across the end-to-end value chain.
EnableEVERYONE
across the value network
A series of projects, externally driven, no
matter how successful or how prolific, will never
build organisational capability to create
end-to-end value chains. That is why TRACC focuses on enabling people, while improving processes and systems simultaneously.
Is this true for your organisation?
“I have some really good status quo managers, but no one that really improves what we do.”
TRACC enables your leaders and their people to put the right amount of rigour, discipline and structure into place to improve your business.
We work with teams of managers, all good at keeping their functions running,
keeping the business on track, keeping costs down and managing their
personnel. These managers are traditionally charged with ‘doing the work’.
What makes the difference is that TRACC builds their capability to challenge
and change the status quo, and create a ‘shadow’ improvement structure. The
same structured cadence of meetings required at different tiers of the business
to manage the business is needed to improve the business. The improvement
‘shadow’ structure is focused on ‘improving the work’ and relies on integrated
data from the TRACC Platform to drive improvement in the business, and track
best practice maturity and KPI performance improvement to target.
ImproveEVERYTHING
“TRACC has a clear road map and plan to transform our plants in Mexico from good to great, giving us the methodology and foundations to be sustainable in the future in order to create a competitive advantage for Kellogg’s Latin America.”
— Fernando Teixeira, Supply Chain Director, Kellogg’s
“Our DPS System (powered by TRACC) has returned $2 billion to the business in the first two years.”
— Paul Mocniak, Program Manager, DuPont Production System, TRACC
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EnableEVERYONE
across the value network
Organisations like SABMiller and DuPont have not just delivered on rapid results improvement projects; they have also had
the insight to realise that the same amount of rigour, discipline and structure required to manage a business is needed to drive
improvement.
They chose the TRACC Solution not only because of its Integrative Improvement System that provides improvement tracking
cadence, but also because it builds capability to sustain step-change improvement across their global operations.
OBJECTIVE OF MANAGEMENTDeliver sustainable business results
(shareholder value)
TASK 1Manage the business
TASK 2Improve the business
Usually there is a defined structure and governance
A formal process is needed to create the structure and governance
Metrics and Projects
Figure 1: The Objective of Management Teams
Organisations that perform well in sustaining business improvement and innovation have developed a rigorous approach
and improvement system to enable the ‘shadow’ structure to improve the business, as shown on the right side of the diagram
above. They have embedded TRACC’s improvement solution in the organisation to create:
• a rigour in identifying, applying and persevering with best practice
• empowerment and skills at all levels, to enable managers to lead improvement as a way of life
To enable this, TRACC delivers these key principles:
1. Involve everyone in improvement.
2. Empower teams to address issues and eliminate the root cause of problems.
3. Identify excellence, interrogate it and implement it in a standardised way.
4. Create a separate ‘shadow’ structure to improve the business.
5. Drive improvement in a structured, maturity-based manner to both systematise improvement and expand best
practices upon sound foundations.
All these points have clear logic, but it is especially with points 4 and 5 that businesses often battle to see the logic, as this is
counter-intuitive. Unless the existing management structure is duplicated to create the mental ‘headspace’ and dedication
where they can separate themselves from the daily grind, they will be pulled back to business-as-usual. TRACC’s approach
(see Figure 2) ensures a separate cadence of meetings, and separate indicators focusing on business practices and improvement
performance outcomes. It is supported by a system to evaluate, guide, capture and then share best practice.
TRACC’s implementation methodology drives business improvement in the ‘shadow’ structure below.
Executive Leadership Committee
Site Steering Commitee
Implementation Task Force
Team Leader Team Leader Team Leader Team Leader
Shift-basedTeam
Shift-basedTeam
Shift-basedTeam
Shift-basedTeam
Figure 2: The ‘shadow’ structure TRACC creates to focus efforts on continuously applying best practice and process improvements to suit the business needs
Setting up an improvement vision and strategy is executed at a strategic level by the Executive Leadership Committee; planning
the structured implementation of an improvement strategy is done at a systemic level by the Site Steering Committee; and
most of the improvement work is executed and owned at the situational level by the Implementation Task Force who guide,
train and help the team leaders and teams to drive best practice, to perform better and to apply their knowledge.
TRACC enables leaders to not just ‘manage’ the business and its people, but to lead people to continually improve service, cost
and cash in the business.
TRACC TrainingAt each stage of best practice maturity, people need new levels of skills to advance the improvement to the next stage,
building organisational capability as they grow. TRACC Training provides:
• Training-of-trainers development to teach internal trainers how to use the TRACC training programmes and materials
• Leadership and team leader development materials
• Team training workshop materials
• eLearning modules
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TRANSACTINNOVATE
Procurement
SOURCE MAKE (OPERATIONS)
Teamwork Asset Care5S Set-up Time ReductionVisual Management QualityFocused Improvement Environmental
SustainabilityEnvironment, Health and Safety
Administrative Excellence
Autonomous Maintenance
DELIVER/RETURN
Warehouse ManagementTransportation Management*
PLAN
Demand PlanningSupply PlanningSales and Operations PlanningIntegrated Business Planning*
Portfolio and Lifecycle Management* Transactional Excellence
ENABLE
Value Chain AlignmentLeading and Managing ChangeHuman Capital
CUS
TOM
ER
SUPP
LIER
What is TRACCTRACC is a business performance improvement solution that delivers
sustainable organisational transformation to continuously improve
SERVICE, COST AND CASH across the end-to-end value chain.
TRACC builds Demand-driven Value Networks through an outside-in approach, from the customer’s customer back through to the
supplier’s supplier.
TRACC is focused on creating capability
and empowerment to deliver reliability and productivity gains in
all your plants.
THE TRACC VALUE CHAIN IMPROVEMENT SOLUTION
* Currently in Development
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The TRACC Methodology
The TRACC methodology focuses on changing mindsets and behaviours to enable your own people to drive the change,
giving your organisation a truly competitive advantage with demonstrable financial impact. A special emphasis is placed
on leadership behaviours. The TRACC Platform provides the ‘How To’ for all the improvement work packages and the
necessary training materials for your organisation to train everyone just-in-time on the improvement journey. This will give them
the motivation and skills needed to drive improvement in their work area every day. To ensure ongoing success, our consultants,
or TRACC Trusted Advisors, assist with coaching and guiding the CoE Department and operational TRACC implementation teams
on their improvement journey.
On this journey to world class, the TRACC methodology focuses on three key drivers:
1. The first, and most important driver, is gaining leadership commitment at all levels, cascading from the top. Leadership
commitment starts with a true belief in the value of integrative improvement, as well as the persistence and discipline needed to
fully engage all employees in the effort, year after year. Leaders must also govern the improvement process to ensure employees
have the tools and skills to both identify and fix problems. This approach ensures that the improvement process is owned and
managed by operations and functional leaders.
2. The second driver is the competency development of these leaders and the internal support resources that are working within
the ‘shadow’ structure which TRACC creates to own and drive the improvement journey.
3. Operational TRACC implementation teams. These internal resources are supported by consultants who guide the journey,
but who are first and foremost there to transfer competency and enable teams to do the work required without armies of
consultants.
TRACC prepares the organisation to move towards achieving world class reliability at Stages 2 and 3. It builds the capability and
commitment required of your people to deliver breakthrough business transformation at Stages 4 and 5 to create:
• A better customer experience
• Increased margins
• Improved velocity
• Optimised assets
Every TRACC best practice is mapped across five stages of maturity and defined by themes which are the components of that best practice,
incrementally developing capability and work improvement.
Operational Performance Improvement Potential: Examples
World Class
Perfo
rman
ce
Practice Maturity
97%96%
95%
94%
1.6 33 years
World Class
Perfo
rman
ce
Practice Maturity
1.6 33 years
The TRACC Framework
Yield %
= Material loss due to
• Spillage
• Rejects
• Rework
• Oversupply
Overall Equipment Effectiveness (OEE)%
= Lost time due to
• Breakdowns
• Minor stops
• Lower speed
• Set-up / Changeover
• Rework
• Rejects
Margin Increase Potential %
• Less waste
• Less downtime
• Fewer breakdowns
• Lower overtime
• Less energy
• Less consumables
• Less water
• Less spares
• Less packaging
• Less maintenance, etc.
Capex Saving Potential %
• Release hidden capacity
8.9%9.9%
10.9%
11.8%
12.5%
20%
28.6%
50%
80%75%
70%
60%
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Successfully developing a solid foundation of reliability in all of the functional areas will take your organisation through to Stage 2
with major improvements in reliability, productivity, engagement and morale. TRACC consultants are there to guide your TRACC
implementation teams and help them maximise the value of TRACC, but your people will own and drive the journey themselves.
At Stage 3, our TRACC consultants provide focused guidance in the areas of value chain alignment and building a Demand-driven Value
Network (DDVN) to drive the true transformational step change. Between Stages 3 and 4, you can expect significant improvements in:
• Service: Perfect Orders or On Time In Full (OTIF)
• Cost: Operational cost reduction in manufacturing, supply chain and administrative operations
• Cash: Inventory reduction and OEE improvement
Our TRACC consultants will help you ensure that your customer segmentation, network analysis and work process integration are focused,
and that the metrics are clear and integrated across functions. Our consultants work closely with your TRACC implementation teams to
display the information in a way that facilitates critical decision-making for leaders and helps them move forward with creating a DDVN.
The TRACC DDVN collaborative teams focus everyone, in every function, on Cost, Cash and Service goals. They empower the people on
the front-line and on the shop floor to take the right actions. It is when you enable this level of ownership and behaviour that you really
begin to see a step change. With TRACC as your journey partner, you will have access to our consultants who draw on significant best
practice implementation experience from a broad cross-section of industries, ranging from small single-site operations to some of the
largest Fortune 500 companies. This enables you to create a sustainable improvement capability with a relatively small team of external
consultants that focuses on guiding and coaching your people, and building the in-house expertise necessary to ensure your improvements
are sustained even after the consultants leave the building.
TRACC Journey Partners
Our reputation for building competitive
capability is reinforced by our ability to enable
our clients’ global workforce.
OPERATIONS BEST PRACTICESBE S T- I N - C L A S S O P E R AT I O N S P R AC T I C E S i n p r o c e s s m a n u f a c t u r i n g d e l i ve r 9 7 % o n - t i m e d e l i ve r y ; 8 9 % ove r a l l e q u i p m e n t e f f e c t i ve -n e s s ; a n d 9 7 % r a w m a te r i a l u t i l i s a t i o n . I n f a c t, yo u c a n e x p e c t to u n c ove r u p to 2 0 % o f n e w l y a va i l a b l e c a p a c i t y f r o m t h e ‘ h i d d e n f a c to r y ’.
Core Improvement Strategy and Enablement Best Practices
Value Chain Alignment
Leading and Managing Change
Human Capital
Foundation Operations Best Practices
Teamwork
5S
Visual Management
Focused Improvement
Environment, Health and Safety
Pillar Operations Best Practices
Autonomous Maintenance
Asset Care
Set-up Time Reduction
Quality
Environmental Sustainability
Administrative Excellence
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The Value Chain Alignment TRACC helps define value chain
strategies and build the capability to balance the interaction
between demand needs, supply capability and product
innovation. It enables the optimisation of supply chain processes
and networks to aligned customer service segments. And it builds
and aligns practices and processes across functional boundaries.
The Value Chain Alignment TRACC enables …
9 Establishment of multidisciplinary structures to coordinate and sustain all improvement efforts
9 Establishment of a common set of cost, asset utilisation, reliability, responsiveness and agility goals that will satisfy customer requirements and shape demand
9 Alignment of performance measures and targets at all levels
9 Visibility and transparency of processes, integration points and wastes
9 Improved integration of supply chain planning and execution processes
9 Establishment of shared information systems and technologies with a high level of data integrity and visibility
9 All stakeholders to understand both the supply chain and their role in it
9 Creation of the necessary governance, risk and compliance structures and processes to ensure ongoing control
9 Prioritisation and guidance of the implementation of supply chain best practices to achieve and sustain required
performance
VALUE CHAIN ALIGNMENT TRACCYou need to align all the elements of the supply chain towards
achieving sustainable performance improvement across the
demand network to deliver optimal value to your end customer.
And to achieve this, you need alignment between the network
of businesses, processes and people involved in supply chain
execution.
Value chains aligned to deliver sustainable performance improvement
Core Improvement Strategy and Enablement
Best Practice
The Leading and Managing Change TRACC supports
organisations that wish to undertake a major change process
in a measured and structured way. It helps achieve sustainable
business improvements by embedding sound methodology into
the DNA of the organisation and that of its people. And it ensures
that, intuitively, your organisation knows the steps that need to
be followed when major changes are required.
The Leading and Managing Change TRACC enables …
9 Detailed implementation plan development and
integration
9 Effective communication and deployment of improvement
plans
9 Alignment and commitment of all key stakeholders to the
change vision
9 Workforce engagement and participation in the
implementation plan
9 Identification and management of improvement strategy
implementation risks
LEADING AND MANAGING CHANGE TRACCYou need to know how to read the changing environment and
develop strategies that translate into new capabilities to remain
competitive. You need to drive meaningful behavioural change
to ensure continuous improvement. And you need to engage and
empower your people at all levels of the organisation to ensure
your improvements are implemented and sustained.
An agile organisation that responds appropriately to change at all levels
Core Improvement Strategy and Enablement
Best Practice
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The Human Capital TRACC aims to bring the HR team into
the organisation’s wider world class end-to-end improvement
journey. It introduces HR policies and procedures in stages to
support growing human capital management maturity. And it
develops the leadership competencies and practices necessary
to drive and maintain improvement results in all functions of
the business.
The Human Capital TRACC enables … 9 Establishment of fully measurable leadership
development practices
9 Introduction of fully measurable HR policies, practices
and services
9 A clear HR strategy aligned to business imperatives and
customer requirements
9 Line management and HR team cooperation and
engagement
9 Sustained performance of HR teams through teamwork,
structured problem-solving, visual measurement and 5S
HUMAN CAPITALTRACCYou need to develop the leadership competencies and
practices of your line managers so that they can grow your
single most important competitive advantage — your people.
You need to put the appropriate HR policies and procedures in
place to support them in their drive to become world class. And
you need to develop the HR team itself to apply best practices,
build capability and deliver service levels that exceed global
benchmarks.
Optimise human capital to sustain superior performance standards
Core Improvement Strategy and Enablement
Best Practice
The Teamwork TRACC is a foundation best practice designed
to improve organisational efficiency and drive down waste
on a daily basis. It ensures that work teams are accountable
for their performance. It takes your teamwork initiatives from
non-existence through the phases of development to be fully
self-directed by your teams. And you decide how far along this
continuum you wish to go.
The Teamwork TRACC enables … 9 Improved quality, productivity and service
9 Greater production flexibility
9 Faster response to technological change
9 Fewer, simpler job classifications
9 Better response to new worker values
9 Attraction and retention of the best people
9 Alignment of the teams around cascaded strategy and goals
9 Increased effectiveness in executing tasks
9 Teams that own and drive CI right at the point of production
TEAMWORK TRACC
You need to develop high performing teams and make excellence
a top priority to meet your organisation’s strategic goals. You
need greater flexibility in the workplace and improved quality,
productivity and services. And you need to develop the unique
and advanced worker skills and close interdependence among
team activities that were once separate in order to achieve this.
Maximise operational effectiveness with high performance teams
Foundation Operations Best Practice
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The 5S TRACC is a foundation best practice that applies the
basic principles of order, cleanliness, ownership, responsibility
and pride. It ensures that work standards are set and sustained
through self-discipline. And it establishes an environment for
other best practices to prosper and for your people to be their
most effective.
The 5S TRACC enables … 9 A clean work environment with everything in its place
9 Improved product quality through clear work standards
and visibility
9 Standards set and sustained through discipline and built-in
checks
9 Improved overall safety performance
9 Decreased equipment deterioration and failure
9 Early detection and elimination of problems and hazards
9 The creation of the necessary foundations for corrective
action, structured thinking and problem-solving
5S TRACC
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 in order to improve
product quality and reduce equipment deterioration, hazards
and injuries.
Discipline, standardisation and orderliness that sustains best practice improvement
Foundation Operations Best Practice
The Visual Management TRACC is a foundation best practice
that drives problem-solving and focused improvement. It
supports performance measurement through the visual display
of information and it enables effective control through visual
controls.
The Visual Management TRACC enables … 9 Accurate and timeous information visually displayed for
decision-making
9 Teams which actively own the information they generate
and act on it as appropriate
9 Teams empowered to drive down waste actively and
improve performance
9 Organisational performance visible and transparent to key
stakeholders
9 Measurement and strengthening of the implementation of
other best practices, e.g. Autonomous Maintenance, Set-up
Time Reduction, and Quality.
VISUAL MANAGEMENTTRACCYou 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, and 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.
Drive problem-solving, decision-making and focused improvement through visual management
Foundation Operations Best Practice
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Portuguese, Russian and Spanish
Currently available in English UK, English US, Dutch, French, German, Italian, Mandarin, Polish,
Portuguese, Russian and Spanish
The Focused Improvement TRACC is a foundation best practice
that ensures the right people own and address the right problems,
at the right time, and with the right tools. It helps you build an
organisation and an approach to business (call it your business
system) which continually identifies and solves problems, and does
so in a way which is totally integrated into all other processes and
practices across the organisation.
The Focused Improvement TRACC enables … 9 Empowered and enabled front-line workers
9 Establishment of effective cascaded lines of support, so that
the right problems are solved by the right people, at the right
time, and in the right way
9 Organisational learning through problem-solving
9 A highly disciplined approach to decision-making
9 An understanding of key losses and their business impact
9 Enhanced teamwork across disciplines
9 The change process to gain momentum and credibility
9 Increased customer satisfaction and reduced product delivery
time
FOCUSED IMPROVEMENT TRACCYou 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
to rigorously eliminate losses, and to improve performance. In this
way, you and your teams yield the returns you know are possible
but which have remained so elusive to date.
Improvement initiatives converted into real ‘value’ with focused improvement
Foundation Operations Best Practice
The Environment, Health and Safety TRACC is a foundation best
practice that 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 …
9 The progressive building of a safety culture within the
organisation
9 Increased productivity and enhanced employee
relationships
9 Prevention of injuries, lost working time and environmental
incidents
9 Improved environmental performance indicators, such as
energy and water consumption
9 Enhanced public image and increased employee morale
9 Continuous improvement of EHS plans and programmes
ENVIRONMENT, HEALTH AND SAFETY TRACCYou need to ensure the well-being of both your employees and
the environment to achieve world class standards. 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
Foundation Operations Best Practice
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Currently available in English UK, English US, Dutch, French, German, Italian, Mandarin, Polish,
Portuguese, Russian and Spanish
The Autonomous Maintenance 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. This delivers improved
equipment utilisation at lower overall cost.
The Autonomous Maintenance TRACC enables …
9 Improved equipment efficiency
9 A reduction in equipment failures, downtime and
maintenance costs
9 A reduction in equipment-related wastes (quality defects,
speed losses, set-ups and adjustment)
9 Improved teamwork between maintenance and production
9 Higher morale with operators’ potential fully utilised
AUTONOMOUS MAINTENANCE TRACCYou need to take a team-based approach to maintenance
activities in order 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 to free up skilled tradespersons for more specialist
activities.
Eliminate 40-60% of unplanned downtime with autonomous maintenance
Pillar Operation Best Practice
The Asset Care TRACC helps entrench business centred
maintenance as a strategic imperative, as the smallest failure
can stop a whole plant. It prevents equipment failures through
the implementation of an effective preventive maintenance
programme. And it uses the analysis of the current failures to
prevent re-occurrence.
The Asset Care TRACC enables … 9 Prevention of equipment failures and losses
9 Condition-based maintenance strategies that reduce costly
shutdowns
9 Regular inspections to ensure correct equipment settings
and operating conditions
9 Quick fault-finding and repair by multi-skilled maintenance
persons with diagnostic tools
9 Better planning and scheduling to reduce maintenance
downtime
9 Maintenance costs reduced to less than 10-15% of overall
manufacturing cost
ASSET CARE TRACC
You need to maintain optimum equipment productivity to
minimise the total life-cycle costs of owning and operating capital
assets. You need to prevent machine failures. And you need
to comply with legal requirements regarding record-keeping,
analysis and inspection.
Eliminate equipment failures and increase output with proper asset care
Pillar Operation Best Practice
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Portuguese, Russian and Spanish
The Set-up Time Reduction TRACC uses the Single Minute
Exchange of Dies (SMED) technique to enable fast changeovers
and set-ups. 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 …
9 Flexibility to respond quickly to changing customer
demands
9 Improved production output and profits
9 Improved equipment utilisation
9 Reduced start-up wastes and rejects through efficient set-
ups
9 Simple, standardised set-up procedures that free up higher
skilled people to focus on improvements
9 Standardisation and consistency of changeovers
SET-UP TIME REDUCTION TRACCYou need to be flexible enough to respond quickly to customer
demands without being bound by costly changeovers and set-
ups. You need to reduce stock-holding levels and lower working
capital requirements through shorter production runs. And you
need to minimise cost and waste to boost efficiency.
Cost, waste and efficiency improved with set-up time reduction
Pillar Operation Best Practice
The Quality TRACC embraces all the elements of TQM, improving
both the quality control and assurance elements in your
organisation. It assists with the application of quality systems and
techniques to improve product and process quality at the source.
And it ensures you achieve quality in a proactive way, as opposed
to being reactive.
The Quality TRACC enables … 9 Improved customer satisfaction and staff morale
9 Reduced rework and rejects, and thus greater profit and less
waste
9 Reduction of waste relating to manpower, machine time
and material
9 Consistent product performance
9 Reliable delivery dates
9 Reduction in the cost of non-conformance
9 Reduction and control of product and process variability,
and increased machine efficiency through centre-lining
QUALITY TRACC
You need to create products that satisfy customer requirements
and produce quality where it matters most — the coalface. You
need to improve the effectiveness of your quality effort over time.
And you need to strive for zero defects or Six Sigma quality levels
in your effort to reach world class.
Exceptional quality that satisfies customer requirements
Pillar Operation Best Practice
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Portuguese, Russian and Spanish
The Administrative Excellence TRACC ensures a systematic
approach to embedding the principles of Lean and process
improvement within your administrative departments. It
supports the implementation of teamwork, 5S, problem-solving
and visual management best practices. And it results in better-
defined service levels, improved service delivery, higher quality,
lower costs and increased customer satisfaction.
The Administrative Excellence TRACC enables …
9 Improved value delivered to customers through Lean
processes and work methods
9 Application of basic planning tools to smooth demand and
create customer pull
9 Improved problem-solving skills to drive performance
improvement projects
9 Teamwork and leadership skills development
9 Management through the visual display of performance
9 Implementation of 5S for discipline, order and efficiency
9 Clear performance indicators and targets (delivery, quality
and cost)
ADMINISTRATIVE EXCELLENCE TRACCYou 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 in order to improve
consistently.
Improved service delivery, quality and cost through administrative excellence
Pillar Operation 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.
The Environmental Sustainability TRACC enables …
9 The identification and management of environmental risk
9 Compliance with environmental legislation
9 Cost savings over the longer term
9 The enhancement of the organisation’s reputation
9 Access to financial markets
9 Increased employee motivation and retention
9 Product market opportunities
ENVIRONMENTAL SUSTAINABILITY TRACCYou 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 in order to achieve both incremental
improvements and step changes in behaviour, technology and
products.
Identify and manage risks with environmental sustainability best practice
Pillar Operation Best Practice
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BEST PRACTICESINCLUDE
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.
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 aquistions and your operation’s
preferred language, making it a scalable source of competitive advantage.
OPERATIONSBEST PRACTICES
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 which keeps everyone engaged.
PLUS TRACC’S THREE CORE IMPROVEMENT STRATEGY AND ENABLEMENT BEST PRACTICES
Human Capital
Value ChainAlignment
Leading andManaging
Change
FocusedImprovement
Autonomous Maintenance
QualityVisual
Management
Teamwork
Set-up Time Reduction
Environmental Sustainability
Environment, Health and
Safety5S
Asset Care
Administration
Excellence
The TRACC Value Chain improVement Solution
To achieve accelerated business performance improvement that is both notable and sustainable, and to continuously increase value, you need to improve everything and enable everyone across your PLAN, SOURCE, MAKE, and DELIVER processes.
More possible tracc best practice solutions for your business ...
TRACC PLANNING BEST PRACTICESYou need to guarantee both planned production that meets forecast demand and the availability of the appropriate amount of raw materials and goods for planned production runs. You need a solution that builds a more agile, flexible and responsive supply chain with an integrated and structured approach to planning.[7 best practices]
TRACC SOURCING BEST PRACTICESYou need to manage complex data, compliance and risk across increasingly global, multi-tier supply chains. You need a solution that helps you reduce the total cost of ownership (TCO) and enables your people to deliver to supply chain KPIs.[4 best practices]
TRACC LOGISTICS BEST PRACTICESYour processes are misaligned and there are activities in your warehouses and across transportation that compromise the management and delivery of your products. You need a solution that organises and coordinates all activities regarding the receiving, storage, preparation and distribution of your products to be on time and delivered in full.[5 best practices]
TRACC TRANSACTIONAL SERVICES BEST PRACTICESYou need to ensure a high level of transactional service in order to increase profit margins, attract new customers and retain existing ones. You need a solution that improves processes, and embeds Lean in the high-volume transactional areas of your business.[4 best practices]
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SERVICESTRACC Trusted Advisors TRACC Trusted Advisors walk every step of the way with your internal implementation and training teams, guiding them through the process, and coaching and training them on how to implement TRACC, build capability, achieve your improvement strategy and sustain the improvements.
SUPPORTTRACC System SupportTo ensure rapid deployment, TRACC provides secure online platform set-up and virtual training. As part of the secure platform set-up, various user groups are created for your organisation. This enables your business to control access rights such as creating and conducting assessments, viewing specific business areas, and system administration.
TRACC CommunityThe TRACC online community of best practice provides a mechanism for TRACC users to see photographic examples of what good looks like. This support service also provides peer networking and discussion forums for shared learning.
TRACC EventsTRACC events are hosted all around the world, attracting thousands of people to collaborate and innovate around business performance improvement. These events are designed to foster collaboration and networking in order to maximise the opportunity for leaders and industry experts to learn from each other’s business improvement programmes, experiences and insights.
TRACCSERVICES AND SUPPORT
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Find out how thiS Solution workS in your induStry:
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Copyright © 2016 CCI (Pty) Ltd All rights reserved TRACC, its logo, and Integrative Improvement System are trademarks of CCI.
Our reputation for building competitive capability is reinforced by our ability to enable our clients’ global workforce.
Our focus on value-based solutions for our clients brings about both practice and work process improvements,
efficiency gains and substantial bottom-line growth.
For over 25 years, we have delivered sustainable results across more than 2 000 operations in 70 countries and in
multiple languages.
Provided by
CCI The PeopleBehind TRACC
ONESOLUTION TO ACHIEVE YOUR IMPROVEMENT STRATEGY
If you are already a TRACC user, please contact your TRACC account manager
Europe ............................. +44-207-321-3902 Africa/Middle East ....... +27-21-555-3610
China ................................ +86-21-3382-1651South East Asia ............. +65-6866-3300 Australasia ...................... +61-75-577-4005
North America .............. +1-949-679-2960 Latin America ................ +52-33-3002-4023
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