FORWARD VISION / PC HENDERSON JOINT NATIONAL TRAINING AWARD

National Training Award Case Study

A Durham company manufacturing garage doors has introduced a continuous improvement programme designed and delivered by Forward Vision, that has given it one of the most highly-qualified management teams in the industry.

Founded in 1921 and with a worldwide reputation for the quality of its garage doors and sliding door gear, PC Henderson looked to the future of its manufacturing operations when it joined the pan-European Cardo group of companies in 2000.

“Direct comparison of costs between group manufacturing plants highlighted the significant challenges that needed to be faced to keep competitive in this new environment” said Operations Director Vicky Brockley.

“In addition, the core UK market for garage doors was becoming ever more competitive as acquisitions saw the number of manufacturers and customers consolidate into larger groups. We could not take market leadership for granted.”

“In a pressurised environment, we inevitably began to receive complaints from the union regarding supervisor treatment of staff. We recognised we needed to change to meet the challenges which faced us.”

Henderson worked with Morpeth-based manufacturing consultancy Forward Vision to develop a training package that would enable everyone to understand the necessity for change, and to understand best practice techniques and how to apply them, and to ensure everyone felt part of the team.

Training began in December 2002. Senior and middle managers attended a series of workshops and seminars, while team leaders and key support staff were given classroom training and workplace assignments.

Leading hands were also given classroom training, in order to deputise for their supervisors when the latter were attending training, and all operators took part in improvement workshops.

“It was essential for management to recognise the potential of the workforce if Henderson was to realise its potential,” said Vicky Brockley. “Eight staff have gained the Diploma in Manufacturing Management and seven the Certificate, underpinning knowledge needed for NVQ Levels 4 and 5.

“Team leaders now work together to solve issues and instead of the 10.7 per cent overspend on labour costs in 2002, we are on budget for the first time in three years. We are 40 per cent under budget on quality costs and on budget with our overheads.

“The return on sales has been improved by 56 per cent, and we have zero grievances regarding team leader behaviour.”

from left to right Ian Lawson (PC Henderson), Peter Tickell (PC Henderson), Caroline McCaulay (PC Henderson), Ian Scurfield (Forward Vision), Vicky Brockley (PC Henderson), Sam Morrison (Forward Vision) and Wendy Gibson (BBC).