Operational Excellence at your Fingertips
Let us help you achieve significant short and long-term results by establishing an operational excellence system
Why us?
- At Zajac Consulting Services Ltd, we take individual approach, tailored to your needs
- Streamlining your operational performance
- Enhancing the quality of your services
- Improving efficiency in operational management using lean manufacturing tools
Areas where we can help you
Choose a tailor-made solution to reach success
Boosting your Manufacturing Performance
We help companies translate their business goals into specific requirements and operating strategies for the supply chain. This avoids confusion and ambiguity in the organization about the relevant targets and key success factors for your supply chain. We use a tailored approach to avoid "one-size-fits" all solutions. This ensures that your organization is able to deliver superior customer value.
Operational Excellence
To reduce cost, optimize lead times, and increase competitiveness we can transform your current operating system so that it does not act as a barrier to progress. Allowing for fundamental system improvements by using ‘smart factory’ design, digital solutions in IT and data analytics for better results and designed for excellence.
Continuous Improvement
Continuous Improvement methodologies once delivered results, and there is still a strong belief that Continuous Improvement is the way forward. But... why isn't Continuous Improvement delivering the expected results anymore?
How do you make progress when Continuous Improvement champions have left, and each site is taking its own approach to Continuous Improvement, without a single overarching Continuous Improvement agenda?
At ZCS, these are familiar challenges. In addition to our Continuous Improvement program and other industrial improvement methods we take a holistic approach to delivering outstanding results. We integrate change management, leadership and digital technology, while maintaining our strong capability to implement global programs and transfer rigorous Continuous Improvement capabilities to our clients.
Our Approach
Our approach always starts with understanding the business context, the data, and our clients’ current situation. This could mean a deep dive into operational management and processes systems, an assessment of IT and operations technologies, or an assessment of the human dynamics such as leadership and behaviors. ZCS aims to create the future of factories in a close tandem manner.
Success Stories
Delivering concrete results
Value Stream Mapping Project (China)
Company profile: Chinese-German JV jet engine MRO facility, responsible for maintenance, repair and overhaul of the most common jet engines used in mid- to long-range commercial aircraft.
Project: Although the purpose of VSM is commonly known as mapping out the entire/core business process, the value stream map created at this particular client involved mapping out one of the repair shops that was commonly considered a "bottleneck". The VSM allowed us to determine that batch processing was causing delays. Further analysis also confirmed that the sequence of certain repair processes were not as efficient as originally planned. In conclusion, we implemented the First In First Out (FIFO) solution and with an aid of the engineering department, we re-sequenced two significant processes and introduced new tooling, allowing the shop to increase its efficiency by 37%, allowing the company to increase the number serviced jet engines annually.
MRP System Implementation (UK)
Company profile: Part of a large interior design group, the company specializes in bespoke kitchen design and manufacture in the South East of England.
Project: This 12 month project involved complete conversion from an 1990-era system to the latest, state of the art MRP system that allowed the company to get get a "fresh start". We lead every aspect of the changeover, including BoM, NC programs, routing and work centers. While working on the system transition, it was also possible to introduce new machinery and provide associate training.
The company is now able to manufacture higher volumes and with such sophisticated system, they are in position to attract new customers with ease.
EV Production Launch (UK)
Company profile: The world's first fully approved manufacturer of the 7.5t electric and hydrogen-electric truck.
Project: Although the company was establish a decade ago. it was only at the beginning of 2022 when it started setting up a fully operational production line in their brand new factory. We supported this project from day one. The factory itself was a "blank canvas" which allowed us to participate in a completely new automotive business launch.
We supported the following areas:
- Complete vehicle build process, including "first truck-first customer" build in September 2022
- Production line re-balancing to achieve takt time in each zone/cell/sub-assembly
- MES system introduction
- Associate hiring process
- Associate training including skill matrices
- BoM change management process
- Battery build process (IMI HV Level 4 consultants only)
The company is now in position to produce 100s of vehicles annually, proving their quality and gaining new customers across the UK and Europe.
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