Client Results

We have not had to look for other solutions as the project with Jason has really worked.

‘It has been just over 12 months since we began the project and the changes we made working with Jason have become part of our culture. Our schedule performance and job status are very visual and it helps all areas of our business understand the progress status of the work and stay on track. The business now has a measuring tool that has supported us achieving 16% sales growth at the same time as reducing our inventory by about 16% also.

Previously we had to turn away work, especially during our busy times as the business was unable to handle it. We had to change as we needed to grow the business to support our markets. We could sell more but could not produce the work for the customers. All of this was effecting me and my people from looking at the business due to the days being taken up with customer enquires relating to late or urgent jobs. I was continually being sucked into day to day manufacturing issues instead of working to improve the business.

These days I am not continually dealing with questions about ‘Where is my job up to’. The system and changes have taken away the worry and the stress. We need this system more than ever as we are continuing to grow. A great factor has been that all have embraced the changes and ran with it. We have not had to look for other solutions as the project with Jason has really worked.’

David Norris – General Manager, Waterloo, Bathurst NSW

In a three month period we eliminated a $100k back order!

Chris Bayliss - Flexco 2

“In 2012 we had significant problems in our manufacturing business. We were late shipping to our distributors who were understandably unhappy, and we spent a fortune on overtime and casuals just to get orders out the door. Our profits were not where we expected them to be, nor where they should have been. Our system and approach to manufacturing was just not good enough. We were reliant on a few key people and change was not happening fast enough. ‘Surprises’ happened too often and were rarely pleasant.

We worked with Manufacturship®  to implement a program to rapidly improve our manufacturing system and the results have been remarkable in financial terms and speed. In a three month period we eliminated a back orders by over $100k and lifted shop floor productivity by so much we have reduced from two shifts to one. We have reduced our labour cost, virtually eliminated overtime and the performance of production is now visible to everyone in the business. Our customer service people can now confidently tell our clients the status of their orders and we have dramatically dropped our lead times.

The quality of our product has improved and most importantly we now have a system that is being used to train more of our staff and management. We have changed the business system more in the last three months than in years and achieved all of this without disruption. The staff are happier and the stress levels have dropped.

If your manufacturing business is not pulling its weight, I’d be surprised if Manufacturship® can’t help you too!”

Chris Bayliss – Managing Director, Flexco, Baulkham Hills NSW

DIFOT of 100% is a normal occurrence

“Before we started working with Jason we had a lot of late orders and many customers ringing us up to see what the ETA was for their job. The phones rang continually. I didn’t believe that DIFOT (Delivery In Full On Time) of 100% was possible.

Now customers do not have to chase their orders and DIFOT of 100% is a normal occurrence. We can be proactive rather than reactive about the business and focus on what is coming up in the future instead of just looking at today.

I come into the office, get a coffee, and walk two laps of the factory without anyone running up to me with an emergency. I now do the job I am paid to do. This is a fantastic feeling for me and for the team.

We worked with Jason as a sounding board; Drawing on his experience in many industries to assist solving our problems has been great, he would either confirm we were on the right track or suggest other approaches that would achieve the desired outcome we were after more effectively. “

Leon Joyce – Director, Larnec Doors, Swan Hill NSW

“We have doubled our sales over a four year period…

…whilst actually having less people in the business. Further, this wasn’t achieved by outlaying huge funds on equipment or Marketing. Conversely it was accomplished by careful calculated fundamental changes to the way the business was run, the only cost was some mental thought and effort, particularly centred around Jason’s process of eliminating bottlenecks and concentrating on the weakest link in the chain.

For a long time we have struggled in one of our main markets with a commodity product and had no competitive advantage. I would visit the major buyers for years and fail to gain any traction. They were happy with their current suppliers and we were a ‘me too’ product. The market value was being destroyed by people competing on a ‘cost per square metre’ basis and we were seeing volume and margin erosion. Working with Jason we researched what the customers really needed, not just what they said they wanted, and have developed significant intellectual property that is patent protected. It has been a long road but we can now sell a system solution to the market that our competitors cannot copy. Volumes are increasing as we are going to market with a total package. We take this product to market in a systematic fashion that is quite different and better than our old approach.

We repeated this market and product development process with a different segment. We would make large protective shade sails on an ad hoc basis when people contacted us. We once again went to examine the broader market and design a superior solution. We have now built a systematic way to communicate to the market about our value and consistently deliver a superior product on time, and on budget to our clients. This ad hoc segment is now core business and a major source of our revenue growth.

We used to be very haphazard about how we ran the business and would often take a shotgun approach to what we would do. Now we are much more in control. We are methodical and plan our approach. Our factory is now efficient and can be relied upon to deliver on time and on quality to our customers even at our increased volumes. Our DIFOT (Delivery In Full On Time) is superior and stable.

The workload is still intense for us and there are times that we still feel that we are ‘under the pump’. Our anxiety levels have dropped, we are more in control, and we all have the feeling that we are ‘getting somewhere’. We manage our time much better and are not worried that we have ‘forgotten something’.

There is more to do yet, but we now know what it is we need to do. This is a huge advantage because having this clear sense of direction allows us to progress much more quickly. On a final note – you can’t do it alone, so we are building the team required to get there – our accountants, legal advice, bankers, suppliers, industry connections, our work-team, and mentors like Jason to bounce ideas against and provide some clear impartial advice.”

Richard Ellis – General Manager, Ellis & Sons, Cowra NSW

We had confidence the whole way through that the project was on time and on budget

“Our track record on previous capital projects was that we were often significantly over budget, over schedule, and began production with a long ‘snag list’ of issues that had to be resolved before production would be stable. This meant that our production costs were up. Often we would fall on our faces before we even knew we had a problem. We knew we needed help.

Using the PFMEA tools Jason & Mike helped us evaluate and mitigate risk well before we had begun to manufacture the system or the product. The critical chain project management approach meant that we were confident that we would hit the project targets. Everyone (internally and externally) was held accountable for their role in the project and the chinks in our armour were exposed early enough for us to take action to avoid any impact on the project.

Ultimately this whole approach is about cost savings or avoidance. We had confidence the whole way through that the project was on time and on budget. The operators were involved and owned the production equipment and system long before we began production on site. The operators are happy and the project has been great value for money. There are no quality issues because of the equipment and we began production at full capacity. This made the job so much easier for everyone!”

Rob Amor – Production Manager, Evoqua (formerly Siemens), Windsor NSW

“We are functioning more smoothly as a team…..we are having conversations that we simply were not able to have two years ago.”

“At the beginning of 2012 the Division put in place a new organisational structure to more effectively align the Division with the needs of the local government sector. As part of this a number of people entered new roles and took on new responsibilities. We recognised that in order for the changes to work we needed to improve our leadership strengths, in addition to being managers.

We have worked with Jason over this period in a series of workshops to train and develop the leadership capabilities within our entire Management Group. The workshops were tailored to match our specific needs, the issues we were facing, and gave us tools and approaches to apply back into the workplace immediately. At the end of every workshop people had an individual and a group plan to take back and run with.

As a consequence of this work our new structure has delivered sooner and we are delivering effective results quickly and in a collaborative manner. We are functioning more smoothly as a team, our staff are happier and we are having conversations that we simply were not able to have two years ago.

The work we have done with Jason throughout this period has helped us reach this point in a faster and smoother way than would have been possible if we had gone it alone.”

Steve Orr – Deputy Chief Executive, Local Government, Nowra NSW

DIFOT of 100% can be done!

“As a new Operations Manager I had a baptism of firePhilBrodbeck - Flexco 250 px in 2013. The business was late shipping to our distributors and end-users, we spent a lot of money on shift penalties and overtime and profitability was poor. Production was a high stress environment where each day was full of unpleasant surprises. Tying down performance levels was like herding cats and we were in a continual state of fire-fighting. The pressure on everyone was intense.

We worked with Manufacturship® to help our situation and the results were immediate. After the initial training we knew where to focus our attention, how to determine if we were truly being effective, rather than efficient, and what to do to ship more product at a lower cost. We rapidly dropped a large back order and I was able to spend time improving the business further because all the fire-fighting stopped. We have fixed the system that has then allowed us to fix the specific parts of the process in order to get a financial return quickly.

Customers can now rely on our delivery dates and our lead time has dropped by half. DIFOT of 100% can be done.

As we saw the results we were achieving Jason asked me “If I had told you before we started that these would be the results, would you have believed me?” I have to honestly say ‘No’ the size of the results, and the speed at which they have been achieved was beyond what I thought possible.

When I first saw the price for the project I did raise my eyebrows but I can now say it was cheap!

We have a system to give us instant visibility. Production is regular, reliable and routine. Quality has improved, more people are now trained, and our financial performance has improved. The project has more than paid for itself in the first three months. We have achieved all this without upsetting people and actually it is now a safer, calmer, and easier place to work for everyone.

If you want a manufacturing operation that is a competitive advantage for your company, you need to talk to these guys!”

Phil Brodbeck – Operations Manager, Flexco, Baulkham Hills NSW

For anyone who wants to develop their Management Skills, Management Perceptions about how to manage their business, you should try this course [Manufacturship® – Transforming Manufacturing Leadership]. It’s a good option!

Peter Lowther – Manufacturing Manager, Custom Group, Milperra NSW

In the next calendar year we expect to put $100,000 to the bottom line

My name’s Christian Kath, I’m the State Operations Manager for Steri Health. I’ve just finished the 3 day Manufacturship® course with Jason and it’s been a fantastic help.

When I first moved from a manufacturing background to a service industry I wasn’t at first sure how I could use the skills and knowledge that Jason has previously taught me and transfer that to a service environment. But with a little extra help and some coaching, we were able to develop a structured process and Jason could show me where bottlenecks and where constraints exist in the service world, as they do in manufacturing.

With a little help we have come up with a detailed plan which I can take back, and in the next calendar year we expect put $100,000 to the bottom line from that.

Christian Kath – State Operations Manager, Steri Health, Yatala QLD

A Rapid Change in Delivery Performance had our sales team asking What Had Happened!

Duncan Greeney Tyco  Testimonial“A year ago I took over the General Manager’s role for the TYCO Water fittings, valve foundry and manufacturing business unit, with Sales of over $45m and more than 180 people. For many years our supply performance to our distribution centres and customers had been poor and none of the previous strategies attempted had made any significant improvements for our end customers. My own team had reached the point where they believed that reducing our overdue orders beyond a certain point was impossible.

Within a couple of months of working with Jason as part of his Executive Mentoring program we had implemented some very simple strategies that reduced our overdue orders down to half what people thought was possible. This made such a rapid change in our delivery performance that our sales division was asking what had happened!

I then used Jason as a trainer with my Lead Team to help us define and build the management system needed so that these gains would continue to occur, the improved performance levels would become normal, and to lock these gains in for the future. Introducing the changes needed with my team is now much easier as the alignment this training created has been tremendous. We are continuing to work with Jason to drop our lead times, reduce our work in progress, and boost our cash flow.

Jason is a straight shooter and draws upon his wealth of experience to help you cut through the noise and find what is holding your business back. The practical, real world based approach Jason uses really works!”

Duncan Greeney – General Manager, TYCO Water, Currumbin QLD

$1,000,000 Reduction in Costs

Simon Spiers Testimonial Sunrice“Sunrice is a large rice processor located in Leeton NSW. We employ well over 150 people and run a multi-shift operation that can run 7 days a week.

Our team members were all working extremely hard, but in different directions. A small numbers of people were depended on to deliver on the results. Team members were constantly waiting to be told what to do. We were all operating at the level below where we were paid to work.

Personally I needed to move from being a reactive manager who was bogged down in the day to day, to a leader who was managing the issues, engaging staff, and getting results financially and in all other areas.

Over a period of 12 months I have had regular mentoring sessions with Jason. We have implemented a simple system that has aligned and focused our leadership team and myself. We combined my personal mentoring sessions with having Jason run some focused training workshops to provide clarity about how to implement the systems and perform our roles more effectively and with less pressure.

I have successfully taken on a larger role as the Site Operations manager with considerably more responsibility. Work is more enjoyable as each day I can see progress on the previous day. Rather than being on the treadmill with little to show for my efforts, working hard is now delivering results!

The Leeton manufacturing group has definitely made some massive improvements in many aspects of the business, especially in quality, safety, cost reduction and people development. The business has taken out at least $1,000,000 of cost in the past 12 months; Jason’s mentoring has been a significant contributor to this.

If a manager wants to improve how they manage, how their team performs and how their business performs, then Jason as a coach would be an excellent investment.”

Simon Spiers – Manufacturing Manager, Leeton Mill, Sunrice, Leeton NSW

Annual Benefit Of More Than 8 Figures

“I have known Jason for nearly 20 years and worked closely with him for the last three years whilst he was at Tom Bell TestimonialElectrolux in Orange.

Manufacturing in Australia is a tough game and is always on a knife edge. Jason led the Orange team of nearly 600 people to reduce costs, increase customer support, set new records for quality and expand export markets. This was done before and during the GFC! All of this without large scale investment and in an incredibly competitive environment with many players.

All of these improvements flowed through to the bottom line in a multi-million dollar annual benefit of more than 8 figures!

If you are a Manufacturer, you need to talk to this guy and hear how he can help you!”

Tom Bell – Senior Vice President Manufacturing Asia Pacific, Electrolux

Found Savings Of $40m In Capital Expenditure

“Jason is a change agent. He defines what the goals should be and engages the workforce at all levels to achieve them.

As Quality Manager for our 1600-person business, he was the unrelenting voice of the customer challenging all areas of manufacturing to see problems from the perspective of the customer.

As Foundry Manager of what was the largest grey iron foundry in the Southern Hemisphere, Jason led the team to change the operations from being typically foundry (dark, dirty, poor safety performance, and modest efficiency performance) into a benchmark operation that was innovative in work processes and working conditions and at the same time making significant improvements in contributions to profitability.

He was then promoted to take charge of a $250m project that was heading towards a major blowout of both cost and timing. Internationally he negotiated with suppliers initiating savings of $40m in capital expenditure, and locally refocused a launch team unsure of its goals, enabling the project of building a new engine factory to be launched on time and back on budget without compromise to quality or safety.”

Vic Beesley – Former Director of Engine Operations, Holden

Executive Team Is More Effective And ‘Tighter’ Than Ever Before

John McKenna - North Coast Community Housing, Nowra NSW

“North Coast Community Housing is a successful non-profit community housing  provider that operates in the Northern Rivers Region of NSW and manages over 870 social housing properties whilst providing accommodation for over 1600 people. We have recovered from a severe financial crunch 8 years ago to be a solid, well performing business. We did realise that to achieve the growth plans we needed to achieve that our leadership performance and the engagement amongst our people needed to improve. Our relationship with our Board was not great, and a number of our staff were frustrated and unhappy. We knew that at this level of productivity we could not move forward and expand the business as we would not be able to handle the increase in workload.

We worked with Jason using a series of workshops to help surface the tensions and struggles that we were having at all levels and to develop clear tools for people to use to resolve the problems and improve their own skills. Jason also worked with some of our team as an Executive Coach to give more focused and specific support in developing their personal leadership skills.

The result has been that we now have a very strong relationship with our Board, our Executive team is more effective and ‘tighter’ than ever before and the staff are happier and more focused. Our lines of communication are more open and we are successfully executing our plans to support our clients, and grow our business using our existing resources and workforce”

John McKenna – North Coast Community Housing, Nowra, NSW

Freed Up $150,000 In Cash Flow

“I’ve been working with Jason Furness for several months now, through his Inner Circle Program, and I’ve learnt a lot in that time. Jason’s experience is in the real world. He has got a lot to teach you.

Some of the things that we’ve taken from Jason’s teaching here at Superbee have been reducing our finished goods inventory by over 50 per cent, which has freed up something like $150 000 of cashflow. As part of that, it’s allowed us to improve our quality and improve our consistency of supply to our customers, which has improved our relationship with them and repeat business.

We’ve cut our lead times down from four weeks to down to one week, which again has improved our business enormously. Jason’s shown us some simple tools to use and a visual scoreboard so all of our staff and all of our people can see what’s going on and work with that process. It’s led to a happier staff, it’s led to easier production scheduling and it’s greatly improved our DIFOT over time.

I couldn’t recommend Jason highly enough. If you’re in manufacturing, you have to speak with this guy.”

Chris Kath – Superbee Honey Factory, Forbes NSW

This video was then…

this is now:

$147 Marketing Campaign Generates $284,449 In Sales

I spent $147 on a Marketing Campaign Jason developed for me and it has generated $284,449 in extra sales in just 6 weeks. I no longer have any worries about not having enough work!

Jason is now also helping me change how I run my factory so that we can continue to produce all this extra work without me having to slave away working the long hours I used to do.

Business Coaching Works!”

Ian (Bart) Bartholomaeus – CEO, Midpro Engineering, Forbes NSW

Financially We Are Back In Control!

“When we metBrumby testimonial  Raving Fans Jason our business had no marketing approach and we ran from week to week managing cash flow.

We worked with Jason to develop a low cost marketing plan that (along with making a great plane) has resulted in a solid pipeline of orders for our Brumby 610 aircraft for the next 4-5 months.

When this happened we realised that we did not have a system that allowed us to manage the aircraft production as well as the other jobs that were coming into the workshop. The workshop was cramped, jobs were taking way too long and we could not confidently tell a customer when they would see their plane completed. Jason then worked with us to put in place a production system that (within 2 weeks) has significantly improved productivity of the workforce and given us transparency of where every job is at.

The peace of mind this gives us has been fantastic. The reduction in stress and confusion amongst everyone has been massive.

Financially we are back in control and I can spend time growing the business knowing that the workshop is running smoothly.”

Paul Goard – Brumby Aircraft Australia, Cowra NSW

Understanding our financials, growing our business

WRL Engineering

“Working with Jason helped us to understand our financials in a way we have never done in our 18 years in business.

We now know where we need to focus our efforts and we have a system to allow us to see our future workload so we know where we are going.

We have improved our Marketing materials and process with a lot more people knowing who we are and what we do.

We are now really proud of the information we send out about our engineering services.

We have plenty more work to do and working with Jason has us started on growing our business and our financial rewards.”

Warren & Jane Lefbvre – CEO’s, WRL Engineering Pty Ltd, Warren NSW

His Ability To Hone In On The Critical Improvement Opportunity To Allow For Immediate Traction Was Impressive!

LAA Suzanne Marshall  Testimonial“Jason is an engaging speaker with a proven approach to improving cash flow, not just talking about it.

I attended his Manufacturing Mentoring training sessions along with a room full of business operators keen to improve their operational results.  His ability to hone in on the critical improvement opportunity to allow for immediate traction was impressive.

Jason applies the Goldratt’s approach to ongoing improvement, and for those that have read “The Goal” by Goldratt will know that this very success approach needs a “Jason” to mentor and coach teams to achieve the exceptional results available to them.”

Suzanne Marshall – Director, Logistics Association of Australia, Parramatta NSW

Working with jason helped me to develop a process to approach and resolve problems

“Working with Jason helped me to understand what we had to improve and how to develop a process to approach and resolve problems. It is hard to do this when sometimes you are just too close to the problem. This really helped in that I did not have to bear the burden of solving problems alone, but could involve the team in the process. The support really helped me through some times where the problems were so large that it was easy to feel we were drowning. We could have some small wins on issues, quickly, and this helped me to keep on coming back and leading more improvements to the business.”

Jacquii Oakroot – Quality Supervisor, Sunrice, Leeton NSW

So What Is It That I Do?

I mentor people in manufacturing businesses to implement Lean Manufacturing, Six Sigma, and if necessary Marketing improvements by providing training and follow up implementation support to achieve things they and others do not believe are possible.

Executive Coaching, Consulting, Lean Training, are all different delivery modes that can be tailored to suit the specific problems that your business is facing.

To find out more…

…about the products we offer and read media articles written about Jason, please browse our site.  To access other great resources then CLICK HERE to return to the home page to join our community.

 

 

 

 
 

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