Situation

A client in chemical manufacturing was facing the challenge of low capacity utilization and increased cost due to the rising number of failed batches. The number of batches requiring rework was higher than targeted.

Intervention

We carried out a comprehensive engagement survey. The analysis helped the client to identify the concern areas. The employees’ disengagement in the manufacturing department was impacting the production and quality of batches.

Our analysis suggested that to engage the employees in manufacturing, leaders must actively and objectively listen to their employees and focus on people initiatives.

Managers were required to provide constructive feedback, instant recognition to their team members, coaching, and creating a positive team environment free of politics.

Benefits

As a result of the intervention, the client was able to reduce the number of failed batches that required rework considerably, resulting in higher capacity utilization and reduced cost of production.