The UK Governments Manufacturing Advisory Service Presentation by

The UK Government’s Manufacturing Advisory Service Presentation by Brian Sainsbury Joint Managing Director, PDA UK Manufacturing Advisory Service MAS

Opportunities for Bulgaria • • Good business environment Favourable tax legislation Exchange rate stability Attractive labour costs Highly qualified people Developing economy Good culture February 2009 March 2009

Report – BG Human Resources Development Dec 2008 Issues to address • • • Labour migration Corruption issues resolved Culture of improvement Low productivity levels – 32. 7% Effective change management & improvement to raise productivity • Training to raise adaptability of employees

UK Manufacturing Advisory Service MAS Suitability of similar scheme for Bulgaria

MAS – Key Points • Established 2002 • Funded by UK DTI (now BERR) and the Regions • Strategic objectives of Government’s Manufacturing Strategy • Offers practical information, advice and assistance to manufacturers, focusing on SMEs

Delivery Structure The MAS Regional Centres 12 Team Network National Regional of Specialists ofwebsite registered Centresand inadditional each helpline region specialist support MAS Scotland MAS North East MAS North West MAS Yorkshire & Humber MAS West Midlands MAS East Midlands MAS Wales MAS East Of England MAS London MAS South West MAS South East

The MAS Core Services • Level 1 – Information, signposting and advice (free) • Level 2 – One to two day free diagnostic advisory visit by MAS manufacturing specialists (100% Funded) • Level 3 – Training events – general and company specific, master-classes, seminars • Level 4 – In-depth consultancy support at costs affordable to SMEs – 10 - 30 days of work, 50% funded • Level 5 – Referrals to other sources of assistance and expertise

MAS In-depth Support • Productivity improvements, Lean Manufacturing, Process improvement, etc • Team building • Improving plant layout and space utilisation • Cutting work in progress • Improving quality and delivery • Helping with materials selection & testing • Design & innovation

MAS types of Support Process and Value stream mapping Factory layout Improvements Cellular Manufacture Introduction of 5 S

Key Success Factors • • • Designed by manufacturers for manufacturers High quality manufacturing specialists Easy to access, no red tape, Hands-on, and practical Flexible approach to problem solving Focused on real benefits • Skills transfer for sustainability – helping companies to help themselves

Recognised by UK Government as being one of the most successful business support schemes ever introduced. Summary Facts: • SME focussed support to improve productivity, quality, innovation • Non-bureaucratic ‘hands on’ practical support • Cost to Government over 7 years Circa £ 65 M • 24, 000 diagnostic reviews and 8, 000 in depth company projects conducted • Impacts ‘Value added’ savings in companies £ 500 M ‘MAS has proved able to deliver real benefits to UK Manufacturers. I congratulate all involved with MAS for the success it has achieved’ Rt Hon Alistair Darling Secretary of State for Trade and Industry

MAS Case Studies in the UK Clothing and Textile Industry • Introduced New Factory Layout • 30% reduction in lead times • More streamlined & efficient

MAS Case Study Textile and Clothing Industry Background Griffin Nuumed equestrian fabric manufacturer used advice from MAS to invest in technology which increased productivity and improved staff morale Manufacturing Concerns Sales growth of 30% in the last year meant that there was a real need to improve productivity and start to use technology MAS Diagnosis Introduce computer controlled fabric cutting machine. Digitise and store existing templates. Use design software to introduce new designs. Improve layout to reduce handling and waste. Results Productivity increase of approximately 40% in the cutting area. Improvement of quality and accuracy of cutting. Improved team work and morale. Reduction in material movement and manual handling.

MAS Case Study Textile and Clothing Industry Background Uniform World is a manufacturer of corporate wear, established in the 1970 s. It has a turnover of £ 370, 000 PA and employs 13 direct staff. Manufacturing Concerns The Company was having to compete with an influx of lower priced imitation imports, putting pressure market and profitability. MAS Diagnosis MAS set up workshops that examined key aspects including how to increase awareness of the Company new markets and creating its own bespoke products Results The Company has successfully re-positioned itself in the premium sector of the corporate wear market, developed key relationships within the supply chain and developed value adding solutions The business has grown by almost 50% in turnover and is achieving better margins.

MAS Case Study Textile and Clothing Industry Background K Stevens (Leicester) Limited have been established for over thirty years as manufacturers and suppliers of quality tapes and trims Results The MAS intervention created a net saving over £ 40, 000 when compared to their original selection of software and hardware. The company also have a clear plan to develop the European market for their products Manufacturing Concern The company needed advice on quality and the implementation of a computerised management control system. MAS Diagnosis The MAS specialist Practitioner helped the company to coordinate their for ISO 9000 and the procurement of a computerised management control system.

Lean Manufacturing – real case study benefits Measure Before After > 300 ~ 25 2 Rework / reject loss rate ~ 10 -15% ~ 0. 5% 3 Pressure / employee fatigue Disjointed production & high stress Stress eliminated Low-difficult High - easy 6 Average cycle time (days) ~ 23 2 to 3 7 Ease of training / understanding low High – multi-skill normal 8 On-time in full to customer 25% >99% ~ 1000 ~ 250 1 Distance travelled (m) 4 Feel-good factor / team-working 5 Communication at all levels 9 Floor-space required (sq. m)

The MAS Process

MAS Quality Check on Improvement Objectives Manufacturing Review Terms of Reference (Proposal) Focused Manufacturing Review • Improvement outcomes • Measures MAS • 10 days Manufacturing Intervention • 30 days Results / Outcomes • Expectations • Satisfaction Agreed with Client Company

MAS Quality Check on Improvement Objectives Manufacturing Review Terms of Reference (Proposal) Focused Manufacturing Review • Improvement outcomes Trial Business & • Measures Manufacturing Review carried out in a Bulgarian Garment • 10 days Company – MAS Manufacturing • 30 days 10/03/09 Tuesday Intervention Quality Check on Improvement Objectives Results / Outcomes • Expectations • Satisfaction Agreed with Client Company

BG Company feedback • Interesting to hear different opinions from outside • Good to have an external view with different eyes • Agreed on identified levels of efficiency and productivity improvements • Also agreed on suggestions to address this • Appreciated the two-way process – Good Will approach • Now feel energised to address improvements identified • Would like help and support in implementing proposed changes

• According to UK MAS clients their business improves by an average of 73, 700 GBP per year when they undertake a MAS project • These improvements are likely to increase and repeat year after year

About us Assystem UK PDA The Proposed project

Assystem UK who we are • Part of the Assystem Group • Offices throughout Europe, Americas and the Far East • 8000+ employees € 650 Million T/O

Assystem UK relevant experience • European Commission – Provided the Technical and Management teams for the SPRINT, INNOVATION and LIFT SMEs support programmes • UK Government – Development and management of the UK’s Manufacturing Advisory Service Programme MAS – Secretariat of EUREKA FAMOS programme • UK Regional Development Agencies – Development of a Productivity support programme for SMEs • EC Accession countries – Latvian Innovation Agency Pilot support programme to improve in manufacturing SME – Estonia Enterprise SME Grant programme

PDA Consulting • Established in 1982 as a consultancy and training organisation, • PDA involved with government grant schemes since 1987. • Strong experience assisting UK manufacturing companies improve performance at all levels. • Since 1997 significant involvement with Bulgarian manufacturing companies supplying UK customers including : BARBOUR, CORUS, UMBRO, NEXT and TESCO. • 35 people in UK on consultancy and admin • 45 people employed in Bulgaria controlling materials, technical and production processes.

PDA Consulting Bulgaria • PDA Manufacturing BG Ltd established in 1997 to manage UK customer orders at Bulgarian manufacturers. • Responsibilities include planning, technical, quality, progress, logistics and finance. • PDA currently working with over 40 BG companies in Clothing, Foundry and engineering products. • BG Productivity now a key issue with UK customers

A Manufacturing Improvement Programme for Bulgaria Our Goal A National programme for Bulgarian SME manufacturers with local delivery and real impact Based on the highly successful UK Government’s MAS programme

Thank you for your attention Further information or copies of presentation slides available